DEMAG DC-Com 1, DC-Com 10, DC-Com 2, DC-Com 5 Operating Instructions Manual

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Distributed by Ergonomic Partners

ales@ErgonomicPartners.com www.ErgonomicPartners.com Tel: 314-884-8884

Operating instructions/accessories/component parts

Demag DC-Com 1 - 10 chain hoist

291113 en GB 214 802 44 720 IS 817

Original operating instructions

Manufacturer

Demag Cranes & Components GmbH PO Box 67 58286 Wetter, Germany

Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative.

Owner

Where in use

Size

Serial number

Year of manufacture

Operating voltage

Control voltage

Frequency

Wiring diagram number

Tab. 1

Fig. 1 Example of a rating plate

Item Designation

1 Manufacturer See above

2 Chain hoist type

Serial no., calendar week, year

of manufacture

Load capacity, group of mecha‐

nisms

5 Chain type, hook path

6 Voltage, frequency

Type of enclosure, insulation

class

8 Ambient temperature

9Motor Type

10 Electric key data

11 Conformity symbol

12 Manufacturer's address See above

Tab. 2

 "Model code", Page 18,

 "Selection table", Page 19

 "Model code", Page 18,

 "Selection table", Page 19

 "Available hoist chains", Page 77,

 "Model code", Page 18,

 "Selection table", Page 19

 "Hoist motor data", Page 20

 "Operating conditions", Page 27,

 "Hoist motor data", Page 20

 "Operating conditions", Page 27

 "Selection table", Page 19,

 "Hoist motor data", Page 20

The metric system is used in this document and all figures are shown with a comma as the decimal separator.

Distributed by Ergonomic Partners

Sales@ErgonomicPartners.com

www.ErgonomicPartners.com

Tel: 314-884-8884

214 802 44/291113

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

General........................................................................................................................................................................ 7

DC-Com chain hoist .................................................................................................................................................... 7

DC-Com documents.................................................................................................................................................... 7

Symbols/signal words.................................................................................................................................................. 7

Information on the operating instructions ....................................................................................................................8

Liability and warranty................................................................................................................................................... 9

Copyright .....................................................................................................................................................................9

Use of spare parts.......................................................................................................................................................9

Definition of personnel............................................................................................................................................... 10

Test and inspection booklet....................................................................................................................................... 10

After-sales service..................................................................................................................................................... 10

Safety ..

General information on safety ................................................................................................................................... 12

Safety signs on the equipment..................................................................................................................................12

Intended use.............................................................................................................................................................. 12

Hazards that can be caused by the machine ............................................................................................................ 13

Responsibility of the owner ....................................................................................................................................... 14

Operating personnel requirements............................................................................................................................ 14

Personal protection equipment.................................................................................................................................. 15

Emergency-stop device............................................................................................................................................. 15

Regular inspections................................................................................................................................................... 16

......................................................................................................................................................................12

3.1

3.2

3.3

3.4

3.4.1

3.4.2

3.4.3

3.5

3.6

3.7

3.7.1

3.7.2

3.7.3

3.7.4

3.7.5

3.8

3.8.1

3.8.2

3.8.3

3.9

Technical data ..

Design overview ........................................................................................................................................................ 17

Model code................................................................................................................................................................ 18

Selection table...........................................................................................................................................................19

Electric key data ........................................................................................................................................................ 20

Hoist motor data ........................................................................................................................................................ 20

Mains connection delay fuse links............................................................................................................................. 23

Supply cables ............................................................................................................................................................ 23

Hook dimension C ..................................................................................................................................................... 24

Noise emission/sound pressure level........................................................................................................................ 25

Transport, packing and storage................................................................................................................................. 25

Safety instructions..................................................................................................................................................... 25

Scope of delivery....................................................................................................................................................... 25

Transport inspection.................................................................................................................................................. 25

Packing...................................................................................................................................................................... 25

Storage ..................................................................................................................................................................... 26

Materials.................................................................................................................................................................... 26

Linings .......................................................................................................................................................................26

Housing .................................................................................................................................................................... 26

Surface protection and paint finish............................................................................................................................ 26

Operating conditions .................................................................................................................................................27

......................................................................................................................................................... 17

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4.1

4.2

4.3

4.4

4.4.1

Technical desc

Drive and brake ......................................................................................................................................................... 28

Gearbox and slipping clutch ..................................................................................................................................... 28

Chain drive ............................................................................................................................................................... 28

Electric equipment..................................................................................................................................................... 28

Control system .......................................................................................................................................................... 28

ription.................................................................................................................................................28

4.4.2

4.4.3

4.5

4.6

4.7

7-segment display for operating status and fault display .......................................................................................... 29

Display of software version, operating hours, number of cycles ............................................................................... 30

Central service enclosure.......................................................................................................................................... 31

Control pendant/control cable height adjustment...................................................................................................... 31

Control pendant ........................................................................................................................................................ 31

5.1

5.2

5.3

5.4

5.5

5.6

5.6.1

5.6.2

5.6.3

5.6.4

5.7

5.7.1

5.7.2

5.8

5.9

5.9.1

5.9.2

5.9.3

5.10

5.10.1

5.10.2

5.10.3

5.10.4

5.11

Assembly.

.................................................................................................................................................................. 32

General...................................................................................................................................................................... 32

Safety instructions for assembly................................................................................................................................ 32

DC-Com chain hoist tightening torques.....................................................................................................................34

Installation procedure................................................................................................................................................ 34

Connecting the control pendant ................................................................................................................................ 35

Control cable ............................................................................................................................................................. 36

Control cable technical data...................................................................................................................................... 36

Handling the control cable......................................................................................................................................... 36

Control pendant height adjustment ...........................................................................................................................37

Mobile control system................................................................................................................................................38

Suspending the chain hoist .......................................................................................................................................40

Supporting structure.................................................................................................................................................. 40

Suspension bracket................................................................................................................................................... 41

Mains connection ...................................................................................................................................................... 42

Circuit diagrams and control boards..........................................................................................................................44

DC-Com 1 - 10 solo hoist circuit diagram..................................................................................................................44

Circuit diagram with E11 - E34 DC travel drive ......................................................................................................... 47

Control board............................................................................................................................................................. 47

Programming parameters with the control pendant .................................................................................................. 49

General...................................................................................................................................................................... 49

Meaning of the buttons..............................................................................................................................................49

Meaning of the parameters ....................................................................................................................................... 49

Starting parameter programming mode .................................................................................................................... 50

Adjusting the lower hook position.............................................................................................................................. 52

6.1

6.2

6.3

6.4

7.1

7.2

7.2.1

7.2.2

7.3

7.3.1

7.3.2

7.3.3

7.3.4

7.3.5

7.3.6

7.3.7

7.4

Putting into service for the first time .

......................................................................................................................... 53

Safety instructions when putting into service for the first time................................................................................... 53

Inspection regulations ............................................................................................................................................... 53

Inspections before putting into service for the first time ............................................................................................ 54

Checks on entering service, handover ...................................................................................................................... 54

Operation.

.................................................................................................................................................................. 55

Safety instructions for operation................................................................................................................................ 55

Switching on ..............................................................................................................................................................56

Checks when starting work ....................................................................................................................................... 56

Function checks ........................................................................................................................................................56

Operation................................................................................................................................................................... 57

Safety during operation .............................................................................................................................................57

Load pick-up.............................................................................................................................................................. 57

Moving the load.........................................................................................................................................................58

Load distribution........................................................................................................................................................58

Emergency-stop device operating function ............................................................................................................... 59

Slipping clutch operating function.............................................................................................................................. 59

Lifting path limiter operating function......................................................................................................................... 59

Emergency stop ........................................................................................................................................................59

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7.5

7.5.1

7.5.2

7.5.3

8.1

8.2

8.3

8.3.1

8.3.2

8.3.3

8.3.4

8.3.4.1

8.3.4.2

8.3.4.3

8.3.5

8.4

8.5

8.5.1

8.5.2

8.5.3

8.5.4

8.5.4.1

8.5.4.2

8.5.5

8.5.5.1

8.5.5.2

8.5.5.3

8.5.5.4

8.5.5.5

8.5.5.6

8.5.5.7

8.5.5.8

8.5.6

8.5.6.1

8.5.6.2

8.5.6.3

8.5.6.4

8.5.6.5

8.5.6.6

8.5.7

8.5.7.1

8.5.7.2

8.5.8

8.5.8.1

8.5.8.2

8.5.9

8.5.9.1

8.5.9.2

8.5.10

8.5.11

8.5.12

Taking the equipment out of operation...................................................................................................................... 60

Taking the equipment out of service when faults occur ............................................................................................ 60

Taking the equipment out of service at the end of the shift....................................................................................... 60

Taking the equipment out of service for maintenance and repairs............................................................................60

Maintenance/repair.................................................................................................................................................... 62

Safety instructions for maintenance and repair work ................................................................................................ 62

Basic maintenance requirements.............................................................................................................................. 63

Regular inspections................................................................................................................................................... 64

Required tests and inspections ................................................................................................................................. 64

Special operating conditions ..................................................................................................................................... 64

Service life of the contactor.......................................................................................................................................64

S.W.P. measures for achieving safe working periods............................................................................................... 65

General...................................................................................................................................................................... 65

Calculating the actual duration of service S ..............................................................................................................66

Example: DC-Com 10-1000 1/1 H5 V4/1 in 1Am ...................................................................................................... 66

GO general overhaul ................................................................................................................................................. 68

Maintenance schedule ..............................................................................................................................................68

Maintenance work .....................................................................................................................................................70

Suspension................................................................................................................................................................ 70

Electric equipment cover........................................................................................................................................... 70

Removing the chain collector box ............................................................................................................................. 71

Operating limit switches (standard for DC-Com 10 with 2/1 reeving)........................................................................ 71

Checking operating limit switches ............................................................................................................................. 71

Checking the operating limit switch actuator ............................................................................................................. 72

Chain drive ................................................................................................................................................................ 73

Checking the sprocket wheel ....................................................................................................................................73

Checking the chain guide.......................................................................................................................................... 73

Checking the guide plate/chain entry plate ...............................................................................................................74

Checking the hoist chain ...........................................................................................................................................74

Chain set scope of supply .........................................................................................................................................76

Available hoist chains................................................................................................................................................ 77

Replacing the chain set............................................................................................................................................. 78

Lubricating the hoist chain......................................................................................................................................... 82

Load hook.................................................................................................................................................................. 83

Checking the load hook............................................................................................................................................. 83

Hook safety catch...................................................................................................................................................... 83

Checking the return sprocket .................................................................................................................................... 83

Replacing the hook with fittings for 1/1 reeving......................................................................................................... 84

Replacing the bottom block (standard) with internal cut-off springs for 2/1 reeving.................................................. 85

Replacing the bottom block (option) with external cut-off springs for 2/1 reeving..................................................... 86

Buffer (only with optional operating limit switches DC-Com 1-10 with 1/1 reeving) .................................................. 86

Checking the cut-off buffers/cut-off springs...............................................................................................................86

Buffer arrangement ................................................................................................................................................... 87

Brake .........................................................................................................................................................................88

Brake assignment...................................................................................................................................................... 88

Check brake wear .....................................................................................................................................................88

Slipping clutch ........................................................................................................................................................... 90

Checking the slipping clutch...................................................................................................................................... 90

Adjusting the slipping clutch ......................................................................................................................................90

Gearbox/oil change ................................................................................................................................................... 91

Replacing the contactor on the control board............................................................................................................ 92

Replacing the control cable....................................................................................................................................... 94

9.1

9.2

9.3

9.4

9.5

Malfunctions/warnings............................................................................................................................................... 96

Safety instructions for malfunctions/warnings ........................................................................................................... 96

7-segment display ..................................................................................................................................................... 96

Operating statuses/general messages...................................................................................................................... 97

Warning messages.................................................................................................................................................... 98

Error messages ......................................................................................................................................................... 99

Disassembly/disposal..............................................................................................................................................100

10.1

11.1

12.1

12.2

12.3

12.4

12.5

12.6

12.7

12.8

12.9

General.................................................................................................................................................................... 100

Accessories ............................................................................................................................................................. 101

Assemblies .............................................................................................................................................................. 101

Spare parts.............................................................................................................................................................. 102

Overview ................................................................................................................................................................. 102

Motor ....................................................................................................................................................................... 103

Parts on the gearbox............................................................................................................................................... 104

Chain drive .............................................................................................................................................................. 106

Hook assembly........................................................................................................................................................ 108

Bottom block with internal cut-off springs (standard) .............................................................................................. 109

Bottom block with external cut-off springs (option).................................................................................................. 110

Electric equipment cover ......................................................................................................................................... 111

Control pendant, control cable, service cover ......................................................................................................... 112

Index.........................................................................................................................................................................................113

214 802 44/291113

1 General

1.1 DC-Com chain hoist

You have purchased a Demag quality product. This chain hoist was manufactured to European standards and regulations in accordance with state-of-the-art en‐ gineering principles. The EC machinery directive requirements are satisfied.

1.2 DC-Com documents

Further documents are available for sub-assemblies/components in addition to these operating instructions. The corresponding documents are supplied as necessary or can be ordered separately – also for special designs or if additional options are ordered which differ from these operating instructions.

Documents

Technical data/catalogues

Operating instructions/component parts

Assembly – Adjustment – Dimen‐ sions

Test and inspection booklet

Tab. 3

Order no.

Demag DC-Pro 1 - 25 chain hoist Demag DCS-Pro 1 - 10 chain hoist

Demag DC-Com chain hoist 203 571 44

CF5-DC/DCM trolley 203 568 44

U11-U34/DC/DCM/DK trolley 203 569 44

RU/EU56 trolley 203 691 44

DC electric accessories 203 656 44

POLU box electric accessories 203 682 44

Clamp-fitted buffer 203 313 44

DC-Pro 1 - 15 chain hoist 214 741 44

DC-Pro 16 - 25 chain hoist 211 033 44

DC-Com chain hoist 214 802 44

DCS-Pro chain hoist 214 827 44

DC-Di chain hoist 211 068 44

DC-Wind chain hoist 211 010 44

PGS parallel gripper 214 095 44

Crane hook adapter 211 240 44

KDDC/UDDC articulated trolley 211 159 44

E11-E34 DC travel drive (I) 214 810 44

E11-E34 DC travel drive (II) (circuit diagrams) 211 229 44

DRC-DC radio control system 214 689 44

DRC-DC radio control system quick-step instructions 211 045 44

DC geared limit switches 211 011 44

KDC chain hoist 211 017 44

DC protective sleeve 203 673 44

Friction force checking device 206 973 44

DC PWM/3ST signal converter 211 094 44

DSC-EX control pendant 214 832 44

DSE10-C control pendant 214 998 44

DC tandem box 211 108 44

VG11-34 EU11-34 dual-output gearbox 211 122 44

DC 1 - 15 guide plate accessories 211 095 44

DSC strain relief device 211 092 44

DC test and inspection booklet 214 745 44

Certificates 235 309 44

203 525 44

1.3 Symbols/signal words

Important safety information and instructions are marked by corresponding symbols and signal words in these in‐ structions. Safety instructions and information must be followed. Exercise particular caution to ensure that accidents, injuries and damage are avoided in such cases. Locally applicable accident prevention regulations and general safety regulations must also be followed.

214 802 44/291113

The documents can be ordered from the relevant Demag office.

DANGER

WARNING

CAUTION

The following symbols and instructions warn against possible injuries or damage and are intended to assist you in your work.

This symbol indicates an immediate hazard which can result in serious injury or death.

– Follow these instructions at all times and be particularly careful and cautious.

This symbol indicates a possibly hazardous situation which might result in serious injury or death.

– Follow these instructions at all times and be particularly careful and cautious.

This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage.

– Follow these instructions at all times and be particularly careful and cautious.

Operating hazard for the machine.

● This symbol indicates information on the appropriate use of the machine.

● This symbol in the operating instructions indicates all warnings which, if not complied with, may result in mal‐ functions or damage.

1.4 Information on the operating instructions

These operating instructions are designed to provide the owner and operator with useful instructions for transport‐ ing, putting into service, operating and maintaining our chain hoists. These operating instructions are an integral part of the machine. Persons entrusted with the various types of work must know and comply with the safety regulations and the oper‐ ating instructions. The machine may only be operated by personnel who are fully familiar with the operating instructions. In particu‐ lar, they contain the "Safety" section and the relevant safety instructions in the working sections of these operat‐ ing instructions. The operating instructions must be available to operating personnel at all times to prevent operating errors and to ensure smooth and trouble-free operation of our products. They must be kept in the immediate vicinity. Demag chain hoists are delivered ready for operation as a complete machine with a control pendant or as partly completed machinery without a control pendant.

Complete machine

Based on Machinery Directive 2006/42/EC, the chain hoist is also designated as a machine in the sense of a complete machine in the following.

For a chain hoist delivered ready for operation in the sense of a complete machine, we confirm conformity with the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity.

Partly completed machinery

These instructions inform the manufacturer of an installation with a chain hoist about:

● basic technical information,

● some typical risks,

● the assembly and operation of the chain hoist.

The instructions contained in this document may be used as the basis for the risk assessment and operating in‐ structions which must be compiled by the manufacturer of the installation in compliance with the Machinery Direc‐

tive.

214 802 44/291113

For operation of the installation, the manufacturer of the installation must provide additional operating instructions as the result of the risk assessment, as required, and inform the owner about any remaining hazards. A declaration of incorporation is enclosed for a chain hoist supplied as partly completed machinery which is as‐ sembled with additional parts to form a machine that is ready for operation. The declaration of incorporation refers to the scope of delivery of the partly completed or non-assembled machinery. The owner must take additional measures to satisfy the safety requirements for the machine before the unit is put into operation. Installation of a partly completed or non-assembled chain hoist to create machinery ready for operation must be carried out in compliance with the information provided by the manufacturer for the machinery. Installation and operating instructions for the chain hoist contained in this document must be observed. A conformity inspection in accordance with the Machinery Directive must be carried out for the assembled ma‐ chine when it is ready for operation and a declaration of conformity must be produced. The information contained in the declaration of incorporation for the chain hoist may be used for the conformity inspection.

1.5 Liability and warranty

All information included in these instructions has been compiled on the basis of the relevant regulations, state-ofthe-art engineering principles and our many years of experience.

These instructions must be read carefully before starting any work on and with the chain hoist, especially before it is put into service for the first time. The manufacturer assumes no liability for any damage which results from the following:

● non-compliance with the instructions,

● inappropriate use,

● untrained personnel,

● unauthorised conversions,

● technical modifications.

Wearing parts are not subject to liability for defects. We reserve the right to incorporate technical modifications within the scope of improving the operating character‐ istics and further development of the product.

1.6 Copyright

These instructions are only intended to be used by people who work with or on the chain hoist. Any and all content, texts, drawings, images and any other information are protected within the sense of copyright law and are subject to further industrial rights. Any misuse is an offence. No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐ ages. Further rights reserved. All industrial rights reserved.

1.7 Use of spare parts

We urgently recommend that only spare parts and accessories approved by us be used. Only then can we ensure the safety and normal service life of the installation. Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of the chain hoist. The use of unauthorised spare parts may render null and void any claims for warranty, service, damages or liabili‐ ty against the manufacturer or his appointed personnel, dealers and representatives.

214 802 44/291113

1.8 Definition of personnel

The manufacturer is the person who:

1. manufactures the equipment under his or her own name and places it on the market for the first time;

2. resells other manufacturers' equipment under his or her own name, whereby the reseller is not considered to

be the manufacturer provided the name of the manufacturer (as in 1.) appears on the equipment;

3. imports the equipment into the country and places it on the market for the first time or

4. exports equipment to another member state of the European Union and hands it over direct to a user in that

country.

Owner Owners (employer, company) are defined as persons who own the machine and who use it as intended or allow it to be operated by suitable and trained persons.

Operating personnel/operator Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper‐ ate the machine. This person must be trained by the owner in accordance with the tasks to be performed.

Trained person Trained persons are defined as persons who have been instructed and trained for the tasks assigned to them and on the possible hazards resulting from inappropriate conduct. Personnel must be informed about the required pro‐ tective devices, protective measures, relevant regulations, codes of practice, accident prevention regulations and operating conditions and must provide verification of their competence. This person must be trained by the owner in accordance with the tasks to be performed.

Specialist personnel Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks, such as installation, setting-up, maintenance and fault elimination. This person must be trained by the owner in accordance with the tasks to be performed.

Qualified electrician Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of electric machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are able to assess the tasks given to them and to identify and eliminate potential hazards. This person must be trained by the owner in accordance with the tasks to be performed.

Experienced technician Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐ cient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regu‐ lations, codes of practice, accident prevention regulations, directives and generally accepted engineering stand‐ ards enabling them to judge the safe operating condition of machines.

Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, Section 23, for determining the S.W.P.) An assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer to determine the remaining duration of service (service life) of the machine (S.W.P. = safe working period) and to carry out a general overhaul of the machine.

Authorised expert engineer (according to BGV D6, Section 28 in the Federal Republic of Germany) In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐ neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐ tual Insurance Association.

1.9 Test and inspection booklet

A test and inspection booklet filled in with all details must be available for the hoist (according to BGV D6 Section 28 in the Federal Republic of Germany). The results of the regular tests and inspections must be entered into the test and inspection booklet and must be certified by the inspector. Test and inspection booklet order no.:  Tab. 3, Page 7.

1.10 After-sales service

If you have any questions on our products or need technical information, please contact our after-sales service.

214 802 44/291113

Please keep the serial or order number (see test and inspection booklet, load capacity plate on the crane) for any correspondence or spare part orders. Specifying this data ensures that you receive the correct information or the required spare parts.

Demag Cranes & Components GmbH Telephone: +49 (0)180 5741268 www.demagcranes.com

214 802 44/291113

2Safety

2.1 General information on safety

The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as well as for safe and reliable operation of the machine. When it is placed on the market, the machine is built according to generally accepted engineering standards and is considered to be safe to operate. It may still be a cause of danger if it is not used correctly or as intended by suitably trained personnel. Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably. Any conversions, modifications or additions to the machine are prohibited unless approved by Demag in writing.

2.2 Safety signs on the equipment

Any pictograms, signs or labels on the machine must be obeyed and must not be removed. Pictograms, signs or labels that are damaged or no longer legible must be replaced immediately.

Fig. 2

2.3 Intended use

The machine may only be used as intended and in compliance with the requirements for the owner and the fol‐ lowing limitations as specified in these operating instructions. Any other use may result in a danger to life and limb and/or cause damage to the machine and/or load.

● Chain hoists are only intended for lifting, lowering and moving loads and may be used as stationary or travel‐ ling units.

● The suspension/support structure for the chain hoist must be designed to accommodate loads resulting from operation of the chain hoist. The maximum safe working load is the load capacity specified on the capacity plate. This must not be exceeded. The maximum permitted load capacity of the chain hoist includes the load and any load handling attachment.

● The machine may only be installed, used, operated, maintained and removed by trained personnel when it is in perfect working order. Personnel must meet the requirements according to  "Operating personnel require‐ ments", Page 14.

● Intended use includes compliance with the safety instructions as well as any other instructions on assembly and disassembly, commissioning, function and operation, maintenance and fault elimination as well as compli‐ ance with the instructions on the machine safety devices, any possible remaining hazards and protection against hazards.

●

The machine may only be used subject to the permissible technical data,  "Technical data", Page 17.

● The machine must be maintained regularly and appropriately by trained personnel in line with the specified deadlines and checked according to  "Maintenance schedule", Page 68. Wearing parts must be replaced in good time.

● UVV/BGV D8, Section 23 (2) and BGV D6 (1) guidelines must be not be ignored.

No liability for inappropriate use The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐ ceptable according to these operating instructions. In particular, the manufacturer assumes no liability for damage due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section.

No liability for structural modifications The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him. This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de‐ livery, or the installation or use of third-party accessories, equipment or sub-assemblies that are not approved by the manufacturer.

214 802 44/291113

Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an expert engineer before it is handed over to the owner. DC chain hoists are designed for operation at temperatures from - 20 °C to + 45 °C. At extreme temperatures and in aggressive atmospheres or conditions differing from those specified in the "Operating conditions" section, the owner must implement special measures after consulting Demag.

Use of the control pendant Powered lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of the corresponding control elements on the control unit. The slow speeds are intended for attaching the load, lifting it free and depositing it. Loads can be precisely positioned at slow speeds. Short transport times can be achieved at higher speeds. They are suitable for travelling without a load or with a safely suspended load if no hazard can be caused by the faster motion sequences.

Inching (flick switching) must be avoided, as it causes increased wear and load sway.

2.4 Hazards that can be caused by the machine

The machine has been subjected to a risk analysis. The design and execution based on this analysis corresponds to state-of-the-art engineering principles. However, residual risks remain.

DANGER

Live components

Danger to life and limb.

Electric energy may cause very severe injuries. Danger of death caused by electric current if the insulation or individual components are damaged.

– Switch the machine off and secure it against restoration of the power supply before any maintenance,

cleaning or repair work is carried out.

– Switch the power supply off before any work is carried out on the electric equipment. Check to ensure that

the components to be replaced are de-energised.

– Do not remove any safety equipment or render it inoperative by modifications.

WARNING

Crushing hazard

Body parts can be crushed when loads are lifted or lowered.

Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered.

Suspended load. Falling parts.

Danger to life and limb if lifted loads are dropped.

Keep out of the danger zone at all times

– Keep a sufficient safety distance.

– Never step under a suspended load.

Certain work and practices are prohibited when using the machine as they may involve danger to life and limb and result in lasting damage to the machine. Observe the safety instructions in the sections:

●

 "Assembly", Page 32

●

 "Putting into service for the first time", Page 53

●

 "Operation", Page 55

●

 "Maintenance/repair", Page 62

214 802 44/291113

2.5 Responsibility of the owner

Information on safety at work refers to the regulations of the European Union that apply when the machine is manufactured. The owner is obliged to ensure that the specified industrial safety measures comply with the latest rules and regulations and to observe new regulations during the entire service life of the machine. Local industrial safety legislation and regional regulations and codes of practice applicable at the site of operation of the machine must be observed outside the European Union. General safety, accident prevention and environmental protection regulations that apply where the machine is in operation must be observed and complied with in addition to the safety instructions contained in these operating instructions. The owner and any personnel authorised by him are responsible for correct operation of the machine and for clearly defining responsibilities for installation, operation, maintenance and cleaning. The operating instructions must be followed in full and without any limitations.

Special local conditions or applications may lead to situations which are not considered in these operating instruc‐ tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing of personal protection equipment. The operating instructions must, if required, be supplemented by the owner with instructions relating to organisation of work, working procedures, authorised personnel, supervising and reporting obligations, etc. For further information, see  "Safety instructions for operation", Page 55.

Furthermore, the owner must ensure that

● any further working and safety instructions resulting from the hazard assessment of the machine workplaces are specified in operating procedures.

● personnel who work with or on the machine are provided with appropriate first-aid equipment. Personnel must be trained in the use of the first-aid equipment.

● the operating instructions are always kept available in the immediate vicinity of the machine for installation, op‐ erating, maintenance and cleaning personnel.

● personnel are trained in accordance with the work to be performed.

● the machine is only operated when in safe and proper working order.

● the safety devices are always kept freely accessible and are checked regularly.

● national regulations for the use of cranes and lifting appliances are observed.

● any specified regular checks and inspections are carried out on time and are documented.

The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these instructions at a suitable place where they can be easily seen.

2.6 Operating personnel requirements

Only authorised and trained personnel may work on the installation. The personnel must have received instruction on the installation functions and any hazards that may occur. Every individual given the task of working on or with the installation must have read and understood the instruc‐ tions before any work starts. Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with the installation. Age and job-specific regulations relevant at the place where the installation is operated must be observed for the selection of any personnel. Personnel are obliged to report to the owner without delay any changes to the installation that impair safety.

For independent operation (operator) or maintenance (trained maintenance fitter) of the installation, the owner may only employ persons

● who are at least 18 years of age,

● who are mentally and physically suitable,

● who have been instructed in the operation and maintenance of the installation and who have proven their quali‐ fication to the owner in this respect.

214 802 44/291113

2.7 Personal protection equipment

When work is carried out on or with the installation, the following protective equipment is recommended to be worn according to the owner's hazard assessment:

● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other jewellery, etc.);

● Safety shoes to protect against falling parts and against slipping;

● Safety helmet to be worn by everybody in the danger zone.

2.8 Emergency-stop device

214 802 44/291113

Fig. 3 Position of the emergency stop (1)

The machine is fitted with an emergency-stop device (1) to prevent damage and injuries. This is located on the control unit. The emergency-stop operating function must be checked regularly.

2.9 Regular inspections

The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation and regional regulations. In Germany, this is specified by the accident prevention regulations for winches, hoists and towing devices (BGV D8) and the accident prevention regulations for cranes (BGV D6), for example. These specify that

● the machine must be inspected before it is put into operation,

● the machine must be inspected regularly,

● the elapsed share of the theoretical safe working period must be calculated,

● a record of tests and inspections must be kept.

The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe new regulations at all times. If no comparable inspection regulations or requirements apply at the place where the machine is operated, we recommend compliance with the above-mentioned regulations.

214 802 44/291113

3 Technical data

3.1 Design overview

214 802 44/291113

Fig. 4 Single-fall design

Item Designation Item Designation Item Designation

1 Electric equipment cover 11 Chain guide 21 Adjusting mechanism for control cable

2 Control system 12 Chain sprocket 22

3 Elapsed operating time counter 13 Round section steel chain 23

Window

14 Slipping clutch 24 Motor shaft

DC 1 - 5 two-stage helical gearbox DC 10 three-stage helical gearbox

5 Pulse wheel for speed monitoring 15 Dished washer pack 25 Winding head cap

6 Magnet brake 16 Slipping clutch adjusting nut 26 Stator

7 Brake disc with linings 17

8 Brake springs 18 Suspension bracket 28 Fan

9 Brake magnet 19 Suspension pin 29 Fan cover

10 Gearbox housing 20 Service cover 30 Mounting points

Tab. 4

Illustration differs from scope of delivery

Cut-off buffer for operating limit switch

Hook assembly with load capacity

plate

27 Rotor

3.2 Model code

E K L D DC-Com 10 - 2000 2/1 H5 V6/1,5 380 - 415 / 50 24/6 200 220 - 480

Travel drive voltage range/

Long trolley

Low-headroom hoist

U Standard-headroom monorail hoist

11 Trolley size load capacity [kg • 100]

Push-travel trolley

E Travel drive

C F 5 Click-fit (push-travel trolley)

Tab. 5

voltage [V]

Max. flange width of the trolley [mm]

Travel speed [m/min]

Frequency [Hz]

Chain hoist voltage range [V]

Lifting speed [m/min]

V 2-stage= Main/creep lifting

VS Stepless = VS at nominal load up to VS

Hook path [m]

Reeving

Load capacity [kg]

Size

DC-Pro product range

DC-Pro 2-stage chain hoist (Demag chain hoist) DC-ProDC 2-stage chain hoist for direct control

DCM-Pro 2-stage Manulift DC-ProCC 2-stage chain hoist for conventional contac‐

DCS-Pro Variable-speed chain hoist

DCMS-Pro Variable-speed Manulift DC-ProFC Variable-speed chain hoist for control by

DCRS-Pro Stepless rocker switch

DC-Com product range

DC-Com 2-stage chain hoist

Articulated trolley

DC-Pro product range

tor control

means of an external frequency inverter

in the partial load range

max

Not all features of the mounting code can be combined.

Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 respectively.

214 802 44/291113

3.3 Selection table

Load ca‐

pacity

Size

Chain

Reeving

Group of mechanisms

DIN EN 14492

from 01/2014 until 12/2013 at 50 Hz at 60 Hz H 4 m 5 m 8 m

Chain size Lifting speed Standard

hook path

Motor size

Max. weight

for hook path

hoist

[kg] DC-Com FEM/ISO FEM/ISO [mm] [m/min] [m/min] [m] [kg] [kg] [kg]

100

160

200

250

315

500

630

1000

1250

2000

2 6,0/1,5 7,2/1,8 ZNK 71 B 8/2

1/1

2/1

4m/M7 3m/M6

3m/M6 2m/M5125

2m/M5 1Am / M4

3m/M6 2m/M5

2m/M5 1Am / M4

3m/M6 2m/M5

2m/M5 1Am / M4

3m/M6 2m/M5

2m/M5 1Am / M4

8,0/2,0 9,6/2,4

4,2x12,2

5,3x15,2 4,5/1,1 5,4/1,3 ZNK 80 A 8/2 27 28 30400

7,4x21,2 4,0/1,0 4,8/1,2

4, 5 and 8

ZNK 71 A 8/2

ZNK 100 A 8/2 47 48 52800

ZNK 100 B 8/2 63 65 731600

21 22 24

Tab. 6

Lifting speeds until 09/2008 (no longer available)

Load ca‐

pacity

Size Reeving Group of mecha‐

nisms

Chain

DIN EN 14492 at 50 Hz at 60 Hz H 4 m 5 m 8 m

Chain size Lifting speed Standard

hook path

Motor size

hoist

[kg] DC-Com FEM/ISO [mm] [m/min] [m/min] [m] [kg] [kg] [kg]

160

250

315

400

500

1/1

2m/M5

1Am / M4

2m/M5

1Am / M4

4,2x12,2

ZNK 71 B 8/4 21 22 24200

4,0/2,0 4,8/2,4 4, 5 and 8

5,3x15,2 ZNK 80 A 8/4 27 28 30

Tab. 7

Max. weight

for hook path

214 802 44/291113

Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 respectively.

Replacement gearboxes for DC-Com units delivered until 12/2013 will be supplied with higher FEM classification as of 01/2014.

Larger hook paths on request.

Motor key data  "Hoist motor data", Page 20.

ZNK 71 A 8/2 with 380-415 V / 50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.

3.4 Electric key data

3.4.1 Hoist motor data

Size Motor size No. of

DC-Com 1 ZNK 71 B 8/2

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

ZNK 100 A 8/2

DC-Com 10

ZNK 100 B 8/2

ZNK 71 A 8/2

12)

DC-Com 1

ZNK 71 B 8/2

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

ZNK 100 A 8/2

DC-Com 10

ZNK 100 B 8/2

DC-Com 1 ZNK 71 B 8/2

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

ZNK 100 A 8/2

DC-Com 10

ZNK 100 B 8/2

Tab. 8

poles

PNCDF9)n

Starts/h Min./max. currents and start-up current

N min.

N max.

10)

max.

IA/I

N max.

[kW] [%] [rpm] [A] [A] [A]

220-240 V, 50 Hz, 3 ~ (CE)

11)

8 0,05 20 720 240 1,75 2,10 2,10 1,45 0,48

2 0,18 40 2950 120 2,10 2,80 2,80 2,75 0,46

8 0,07 20 695 240 1,80 2,10 2,35 1,45 0,52

2 0,30 40 2880 120 2,30 2,80 3,20 2,75 0,55

8 0,10 20 720 240 1,90 1,90 2,15 2,50 0,46

2 0,41 40 2910 120 3,60 4,70 5,50 4,70 0,49

8 0,19 20 705 240 2,80 3,10 3,65 1,90 0,48

2 0,75 40 2850 120 3,50 4,00 4,50 4,85 0,65

8 0,37 20 735 240

2 1,50 40 2955 120

380-415 V, 50 Hz, 3 ~ (CE)

11)

8 0,05 20 700 240 0,95 1,10 1,10 1,20 0,66

2 0,18 40 2840 120 1,20 1,40 1,40 2,60 0,57

8 0,05 20 700 240 1,00 1,20 1,20 1,45 0,48

2 0,18 40 2840 120 1,20 1,60 1,60 2,75 0,46

8 0,10 20 675 240 1,00 1,20 1,35 1,45 0,52

2 0,37 40 2825 120 1,30 1,60 1,85 2,75 0,55

8 0,18 20 665 240 1,10 1,10 1,25 2,50 0,46

2 0,72 40 2745 120 2,10 2,70 3,20 4,70 0,49

8 0,27 20 690 240 1,60 1,80 2,10 1,90 0,48

2 1,10 40 2745 120 2,00 2,30 2,60 4,85 0,65

8 0,57 20 675 240 3,90 4,60 5,40 2,30 0,42

2 2,30 40 2790 120 5,40 6,30 7,70 5,10 0,49

500-525 V, 50 Hz, 3 ~ (CE)

11)

8 0,05 20 720 240 0,75 0,95 0,95 1,45 0,48

2 0,18 40 2925 120 0,90 1,25 1,25 2,75 0,46

8 0,10 20 675 240 0,80 0,95 1,10 1,45 0,52

2 0,37 40 2825 120 1,10 1,25 1,45 2,75 0,55

8 0,18 20 665 240 0,90 0,90 1,00 2,50 0,46

2 0,72 40 2745 120 1,70 2,15 2,55 4,70 0,49

8 0,27 20 690 240 1,30 1,40 1,70 1,90 0,48

2 1,10 40 2745 120 1,70 1,80 2,00 4,85 0,65

8 0,57 20 675 240 3,30 3,70 4,30 2,27 0,42

2 2,30 40 2790 120 4,15 5,00 6,10 5,13 0,49

cos

φN

DC-Com 2–10 CDF 15/25% until 12/2013

10)

= maximum rated current for lowering motion.

max

11)

Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2 % are possible. Motors are rated to insulation class F.

12)

ZNK 71 A 8/2 with 380-415 V / 50 Hz only for first delivery; a ZNK 71 B 8/2 motor is supplied for replacement requirements.

214 802 44/291113

Size Motor size No. of

DC-Com 1 ZNK 71 B 8/2

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

ZNK 100 A 8/2

DC-Com 10

ZNK 100 B 8/2

DC-Com 1 ZNK 71 B 8/2

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

ZNK 100 A 8/2

DC-Com 10

ZNK 100 B 8/2

DC-Com 1 ZNK 71 B 8/2

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

ZNK 100 A 8/2

DC-Com 10

ZNK 100 B 8/2

DC-Com 1 ZNK 71 B 8/2

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

ZNK 100 A 8/2

DC-Com 10

ZNK 100 B 8/2

Tab. 9

poles

PNCDF

13)

Starts/h Min./max. currents and start-up current

N min.IN max.

max.

14)

IA/I

N max.

[kW] [%] [rpm] [A] [A] [A]

220-240 V, 60 Hz, 3 ~ (CE /

CSAUS)

15)

8 0,06 20 870 240 2,10 2,50 2,50 1,45 0,47

2 0,22 40 3525 120 2,50 3,35 3,35 2,75 0,45

8 0,09 20 845 240 2,10 2,50 2,80 1,45 0,51

2 0,36 40 3480 120 2,70 3,30 3,85 2,75 0,54

8 0,12 20 870 240 2,30 2,30 2,60 2,50 0,45

2 0,49 40 3510 120 4,40 5,60 6,60 4,70 0,48

8 0,23 20 855 240 3,35 3,75 4,40 1,90 0,47

2 0,90 40 3450 120 4,20 4,80 5,40 4,85 0,67

8 0,44 20 885 240

2 1,80 40 3555 120

380-400 V, 60 Hz, 3 ~ (CE)

15)

8 0,06 20 870 240 1,35 1,60 1,60 1,45 0,47

2 0,22 40 3525 120 1,70 2,00 2,00 2,75 0,45

8 0,09 20 845 240 1,40 1,60 1,70 1,45 0,51

2 0,36 40 3480 120 1,80 2,00 2,20 2,75 0,54

8 0,12 20 870 240 1,55 1,55 1,75 2,50 0,45

2 0,49 40 3510 120 3,00 3,50 4,10 4,70 0,48

8 0,23 20 855 240 2,30 2,50 2,80 1,90 0,47

2 0,90 40 3450 120 2,70 2,90 3,30 4,85 0,64

8 0,44 20 885 240 5,75 6,40 7,10 2,30 0,41

2 1,80 40 3555 120 7,30 8,90 10,00 5,10 0,48

15)

440-480 V, 60 Hz, 3 ~ (CE /

CSAUS)

8 0,06 20 870 240 0,96 1,15 1,15 1,45 0,47

2 0,22 40 3525 120 1,15 1,55 1,55 2,75 0,45

8 0,09 20 845 240 1,05 1,25 1,40 1,45 0,51

2 0,36 40 3480 120 1,35 1,70 1,95 2,75 0,54

8 0,12 20 870 240 1,15 1,15 1,30 2,50 0,45

2 0,49 40 3510 120 2,20 2,80 3,30 4,70 0,48

8 0,23 20 855 240 1,65 1,85 2,20 1,90 0,47

2 0,90 40 3450 120 2,10 2,40 2,70 4,85 0,64

8 0,44 20 885 240 4,10 4,80 5,60 2,30 0,41

2 1,80 40 3555 120 5,60 6,60 8,00 5,10 0,48

15)

575 V, 60 Hz, 3 ~ (CE /

CSAUS)

8 0,06 20 870 240 1,10 1,10 1,22 0,49

2 0,22 40 3525 120 1,20 1,20 3,50 0,41

8 0,09 20 845 240 0,80 0,90 1,65 0,60

2 0,36 40 3480 120 1,00 1,15 2,75 0,55

8 0,12 20 870 240 0,95 1,10 2,50 0,45

2 0,49 40 3510 120 1,80 2,10 4,70 0,48

8 0,23 20 855 240 1,30 1,50 2,20 0,46

2 0,90 40 3450 120 1,60 1,80 5,70 0,73

8 0,44 20 885 240 3,00 3,50 2,33 0,43

2 1,80 40 3555 120 3,90 4,70 5,60 0,60

cos

φN

214 802 44/291113

13)

DC-Com 2–10 CDF 15/25% until 12/2013

14)

= maximum rated current for lowering motion.

max

15)

Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2 % are possible. Motors are rated to insulation class F.

Lifting speeds until 09/2008 (no longer available)

Size Motor size No. of

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

Tab. 10

poles

PNCDF n

Starts/h Min./max. currents and start-up current

N min.

N max.

16)

max.

IA/I

N max.

[kW] [%] [rpm] [A] [A] [A]

220-240 V, 50 Hz, 3 ~ (CE)

17)

8 0,09 15 665 240 2,10 2,20 2,50 1,25 0,52

4 0,18 25 1405 120 2,10 2,10 2,40 2,30 0,56

8 0,18 15 710 240 2,60 2,90 3,30 1,70 0,49

4 0,36 25 1455 120 3,10 3,80 4,50 2,70 0,52

380-415 V, 50 Hz, 3 ~ (CE)

17)

8 0,09 15 665 240 1,20 1,30 1,45 1,25 0,52

4 0,18 25 1405 120 1,20 1,20 1,40 2,30 0,56

8 0,18 15 710 240 1,50 1,70 1,90 1,70 0,49

4 0,36 25 1455 120 1,80 2,20 2,60 2,70 0,52

500-525 V, 50 Hz, 3 ~ (CE)

17)

8 0,09 15 665 240 1,00 1,05 1,15 1,25 0,52

4 0,18 25 1405 120 0,85 0,95 1,10 2,30 0,56

8 0,18 15 710 240 1,20 1,35 1,50 1,70 0,49

4 0,36 25 1455 120 1,45 1,75 2,05 2,70 0,52

220-240 V, 60 Hz, 3 ~ (CE/CSA)

17)

8 0,11 15 815 240 2,50 2,70 3,00 1,25 0,51

4 0,22 25 1705 120 2,50 2,50 2,90 2,30 0,55

8 0,22 15 860 240 3,10 3,50 4,00 1,70 0,48

4 0,43 25 1755 120 3,80 4,60 5,45 2,70 0,51

380-400 V, 60 Hz, 3 ~ (CE)

17)

8 0,11 15 815 240 1,70 1,70 2,00 1,25 0,51

4 0,22 25 1705 120 1,45 1,60 1,80 2,30 0,55

8 0,22 15 860 240 2,00 2,25 2,40 1,70 0,48

4 0,43 25 1755 120 2,60 2,75 3,30 2,70 0,51

440-480 V, 60 Hz, 3 ~ (CE/CSA)

17)

8 0,11 15 815 240 1,25 1,35 1,50 1,25 0,51

4 0,22 25 1705 120 1,25 1,25 1,45 2,30 0,55

8 0,22 15 860 240 1,55 1,75 2,00 1,70 0,48

4 0,43 25 1755 120 1,90 2,30 2,70 2,70 0,51

575 V, 60 Hz, 3 ~ (CSA)

17)

8 0,11 15 815 240 0,95 1,10 1,25 0,47

4 0,22 25 1705 120 0,95 1,10 2,30 0,57

8 0,22 15 860 240 1,20 1,35 1,70 0,44

4 0,43 25 1755 120 1,45 1,70 2,70 0,49

cos

φN

16)

= maximum rated current for lowering motion.

max

17)

Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2 % are possible. Motors are rated to insulation class F.

214 802 44/291113

3.4.2 Mains connection delay fuse links

CAUTION

For safety reasons, we recommend the use of 3-pole automatic circuit breakers/circuit breakers (to DIN EN 60898-1, tripping characteristic B or C) instead of separate fuse links. This arrangement ensures that all phases are disconnected from the power supply in the event of a short circuit.

Voltage 220-240 V 380-415 V 500-525 V 220-240 V 380-400 V 440-480 V 575 V

Frequency 50 Hz 60 Hz

Size Motor size [A] [A] [A] [A] [A] [A] [A]

DC-Com 1

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2

DC-Com 10

Tab. 11

ZNK 71 A 8/2

ZNK 71 B 8/2

ZNK 100 A 8/2

ZNK 100 B 8/2 - 10 10 - 16 10 6

10 10

Mains connection fuse link for lifting speeds until 09/2008 (no longer available)

Voltage 220-240 V 380-415 V 500-525 V 220-240 V 380-400 V 440-480 V 575 V

Frequency 50 Hz 60 Hz

Size Motor size [A] [A] [A] [A] [A] [A] [A]

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4

Tab. 12

666 666 6

666

3.4.3 Supply cables

Supply cables

Voltage 220-240 V 380-415 V 500-525 V 220-240 V 380-400 V 440-480 V 575 V

Frequency 50 Hz 60 Hz

Size Motor size

DC-Com 1

DC-Com 2 ZNK 71 B 8/2

DC-Com 5 ZNK 80 A 8/2 67 56

DC-Com 10

Tab. 13

Supply cables for lifting speeds until 09/2008 (no longer available)

Voltage 220-240 V 380-415 V 500-525 V 220-240 V 380-400 V 440-480 V 575 V

Frequency 50 Hz 60 Hz

Size Motor size

DC-Com 2 ZNK 71 B 8/4

DC-Com 5 ZNK 80 A 8/4 67 56

Tab. 14

18)

for 5% voltage drop ΔU and starting current I

[m]

[mm

]

ZNK 71 A 8/2

1,5

[m]

]

[mm2]

100

ZNK 71 B 8/2

ZNK 100 A 8/2 34 29 80

ZNK 100 B 8/2 - - 38 61 - - 26 43 59

[mm

[m]

[mm2]

1,5

1,5 100 1,5 100 1,5

100

[m]

[mm2]

1,5

[mm2]

[m]

[mm2]

100 1,5

[m]

[mm2]

[m]

100

[m]

[mm2]

1,5

[mm2]

1,5 100 1,5 100 1,5 100

100

[m]

[mm2]

1,5

[mm2]

[m]

100

[m]

[mm2]

1,5

[mm2]

[m]

100

[m]

214 802 44/291113

18)

The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.

3.5 Hook dimension C

Fig. 5

DC-Com with short suspension bracket

(optional)

B DC-Com with long suspension bracket F

Tab. 15

Size Reeving

DC Com 1/2

DC-Com 5 ZNK 80 … 362 395 425 400 435 465

DC-Com 10

Size Reeving Trolley at right angles to the girder Parallel to girder

DC Com 1/2

DC-Com 5

DC-Com 10

Tab. 16

1/1

2/1 ZNK 100 B 8/2 552 632 585 665

1/1

2/1 U22 / U34 649 679 679 663 703 803

Motor size

ZNK 100 A 8/2

ZNK 100 B 8/2

19)

ZNK 71 … 315 335 365 353 373 403

U11 405 425 455 400 420 450

CF 5 395 415 445 390 410 440

U11 452 487 517 447 482 512

CF 5 442 477 507 437 472 502

U11 545 578 667 569 602 672

U22 557 590 679 571 614 703

CF 5 trolley

at right angles to the girder

CF 5 trolley parallel to the girder

CC1 C C1

Chain collector Chain collector

H4 / H5 H8 H4 / H5 H8

Short suspension bracket

460

493

582 615

20)

582 493

U11 - U34 trolley

at right angles to the girder

U11 - U34 trolley

parallel to the girder

Long suspension bracket

20)

526

615

19)

Higher lifting speeds may require the use of larger chain collector boxes, see  "Buffer arrangement", Page 87

20)

Dimensions C and C1 decrease when a short suspension bracket is used: by 38 mm for DC-Com 1-5 and by 33 mm for DC-Com 10.

214 802 44/291113

3.6 Noise emission/sound pressure level

Sound pressure level (L

Type DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10

Lifting speed up to [m/min] 8 6 4,5 4

Sound pressure level [dB (A)]

Tab. 17

) to DIN 45635 at a distance of 1 m from the chain hoist is:

pAF

These noise emission levels were measured under maximum load.

The following structural influences were not considered in the above measurements:

● transmission of noise via steel structures,

● reflection of noise from walls, etc.

3.7 Transport, packing and storage

3.7.1 Safety instructions

WARNING

Falling parts

Risk of injury from falling parts during transport, loading and unloading operations.

– Do not walk under the suspended load. Keep a sufficient safety distance.

– Cordon off a large area around the working zone.

65+

69+

WARNING

Damage caused during transport

The chain hoist may be damaged or destroyed by inappropriate transport.

Attach lifting and handling equipment only at the correspondingly marked points.

3.7.2 Scope of delivery

If special designs or additional options are ordered or the latest technical modifications are incorporated, the ac‐ tual scope of supply may differ from the data and information as well as from the illustrations described here. If you have any questions, please contact the manufacturer.

3.7.3 Transport inspection

● Check the delivery to ensure it is complete and for any transport damage immediately on receipt.

● If any transport damage is visible from the outside, do not accept the delivery or only on condition. Note the scope of damage in the shipping documents/delivery note of the forwarding company. Lodge a claim.

● Lodge a claim for any defects as soon as they are detected, since claims for damages may only be asserted within the relevant claim notification periods.

3.7.4 Packing

Demag chain hoists, the accessories and the trolleys are shipped in cardboard packing. If no agreement has been made on the return of the packing material, separate the materials according to type and size and make them available for further use or recycling.

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Environmental protection:

● Always dispose of packing materials in an environmentally compatible way and according to locally applicable disposal regulations.

● If required, utilise the services of a recycling company.

3.7.5 Storage

Until they are installed, the equipment and accessories must be kept closed and may only be stored under the following conditions:

● Do not store outdoors.

● Store in dry and dust-free places, relative air humidity: max. 60%.

● Do not expose to aggressive media.

● Protect against direct sunlight.

● Avoid mechanical vibrations.

● Storage temperature: -25 to +70 ℃.

● Avoid strong temperature fluctuations (condensation).

● Oil all bare machine parts (rust protection).

● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust protection.

● If stored in a damp location, the equipment must be packed tight and protected against corrosion (use desic‐ cant).

3.8 Materials

3.8.1 Linings

We only use asbestos-free slipping-clutch and brake linings.

3.8.2 Housing

The housing of the chain hoist is made of strong and light-weight die-cast aluminium. The fan cover on the motor, the service cover, the electric equipment cover and the movable chain collector box are of particularly impact-re‐ sistant plastic material.

3.8.3 Surface protection and paint finish

As standard, the chain hoist is provided with corrosion protection (powder coating/paint finish) and supplied in the following colours:

Paint finish

Chain hoist RAL 5009 Azure blue

Load hook and suspension bracket RAL 9005 Jet black

Trolley RAL 5009 Azure blue

Tab. 18

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3.9 Operating conditions

CAUTION

Operational safety risk

Safe operation is only possible under the specified conditions. Contact the manufacturer if the operating condi‐ tions differ from those specified  "After-sales service", Page 10

The chain hoist and the trolley can be operated at:

Ambient temperature: -20 °C to +45 ℃,

Humidity: max. 80 % relative humidity,

Height: up to 1000 m above sea level,

Type of enclosure: IP55,

Electromagnetic compatibility: Resistance to interference in industrial environments,

Tab. 19

Demag chain hoists operating outdoors should be provided with a cover for protection against the weather or chain hoists, trolleys and travel drives should be kept under shelter if they are not in use.

Special operating conditions may be agreed with the manufacturer in individual cases.

Such operating conditions may occur in the following applications, for example:

● Galvanising or electroplating facilities,

● Hygiene areas,

● Low or high temperature applications.

Interference emission for residential, commercial and light-industrial environ‐

ments.

On request, suitably optimised equipment and important information for safe, low-wear operation can be supplied for these applications.

Stronger cut-off springs need to be used under certain circumstances:

● DC1-10 with 1/1 reeving hook assembly – use of cut-off springs (optional)

- for very high mechanical demands on the buffers, e.g. frequenct contact with sharp edges,

- for extreme ambient conditions (high-temperature applications, foundries, etc.).

● DK10 bottom block with external cut-off springs (optional)

- for extreme ambient conditions (high-temperature applications, foundries, etc.).

Reduced duty factor at increased ambient temperatures

If DC chain hoists are operated at ambient temperatures that differ from  Tab. 19, Page 27, the duty factor must be reduced:

Ambient temperature -20 °C to +45 °C >+45 ℃ to +50 ℃ >+50 °C to +55 °C >+55 ℃ to +60 ℃

Chain hoist range Duty factor [%]

DC-Pro DCM-Pro DC-Com 1

DC-Com 2-10 15 / 25 15 / 25 15 / 25 10 / 20

Tab. 20

20 / 40 15 / 35 15 / 25 10 / 20

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4 Technical description

4.1 Drive and brake

A robust pole-changing AC asynchronous motor is used as the hoist motor. The brake is arranged on the load side in such a way that the load is safely braked and held if the slipping clutch is tripped. The brake is released electrically. Pressure springs ensure that the brake is applied automatically when power to the motor is switched off or if there is a power failure. The motor is automatically switched off and, at the same time, the brake is applied when the slipping clutch is tripped and if errors occur. The lifting drive first decelerates by switching from fast speed (2-pole winding) to creep speed (8-pole winding). Mechanical braking occurs when the creep lifting speed has almost been reached. The mechanical brake is applied as soon as the emergency-stop is actuated, regardless of the lifting speed. Wear of the mechanical brake is significantly reduced by electric and regenerative braking of the motor.

4.2 Gearbox and slipping clutch

ADrives BBrakes

1 Slipping clutch 4 Speed detection

2 Motor 5 Brake

3 Chain drive 6 Gearbox

Tab. 21

Fig. 6 Parts in which the load is borne

4.3 Chain drive

The special Demag chain is of high-strength ageing-resistant material with a high degree of surface hardening, galvanised with additional surface treatment. The dimension tolerances of this chain have been precisely adapted to the chain drive. We therefore urgently recommend that the Demag special chain be used to ensure safe opera‐ tion. The maximum service life of the chain can only be reached if the specified regular lubrications are correctly carried out. The entire chain drive is always replaced when a chain is replaced. A chain set which can be easily replaced is available for this purpose.

The chain set offers the following benefits:

● the optimum duration of service is ensured for the chain;

● certainty that the individual chain drive components are replaced when necessary;

● reduction in service costs by replacement and installation in one step; the motor and gearbox do not need to be disassembled.

The slipping clutch is arranged between the motor shaft and the gear‐ box input shaft. In connection with the limit stops on the chain, it per‐ forms the function of the emergency limit stop device for the highest and lowest hook position and protects the Demag chain hoist against overload. The additional electric operating limit switches (standard for DC-Com 10 with 2/1 reeving, optional for DC-Com 1-10 with 1/1 reev‐ ing) for the highest and lowest hook positions prevent the slipping clutch from being approached as an emergency limit stop device during normal operation. The slipping clutch also fulfills the EC Machinery Di‐ rective requirements for a load control device for load capacities as of 1000 kg. The brake arranged on the load side prevents the load from slowly dropping when the unit is at rest. Monitoring of the slipping clutch and automatic cut-out of the drive if slip occurs increase the service life and protect the slipping clutch against overload and incorrect use. The gear‐ box is maintenance-free for up to 10 years.

4.4 Electric equipment

4.4.1 Control system

The chain hoist is fitted with a 24 V contactor control system. The contactor control system is supplemented by an electronic system with programmed functions. This electronic system detects the control commands that are trig‐ gered by the operator with the control pendant. Permissible control commands generate switching commands for the contactors to control the hoist motor. The electronic system monitors the control sequence specified by the operator based on the speed feedback from the drive shaft, the operating limit switch contacts and, if applicable,

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from the thermal contacts in the motor. In there are any discrepancies, the chain hoist is automatically brought to a safe status and warning or error messages are generated. The positively disconnected emergency-stop contact on the control pendant immediately opens the circuit for the contactor supply so that the motor is de-energised and the brake is applied.

As standard, the control system features the following characteristics:

● Operating limit switches for lifting and lowering (optional for DC-Com 1 - 10 with 1/1 reeving, standard for DCCom 10 with 2/1 reeving);

● Plug-in connections for control pendant, power supply, motor connection, brake, operating limit switches;

● Connection for the E11 – E34 trolley control system;

● 7-segment display for operating hours, operating status and error messages;

● Infrared interface for wireless transmission of service data;

● Replaceable socket-mounted contactor.

● Signal transmission in steps with 24 V tri-state signals for controlled DC chain hoists (half-wave evaluation);

Demag control pendants are connected via plug-in connectors for manual control. Compact DSC control units, which are optimised for for Demag DC chain hoists without electric trolleys, are used for such applications; DSE-10C units are used for applications with electric trolleys.

Please refer to the information contained in the "DC electric accessories" document  Tab. 3, Page 7 for inte‐ grating DC chain hoists into existing installations with contactor control. A Polu box with integrated contactor control is needed to control pole-changing AC motors (with or without a brake) of long and cross-travel units, see "Polu box electric accessories" document  Tab. 3, Page 7.

4.4.2 7-segment display for operating status and fault display

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Fig. 7

The 7-segment display is arranged on the control board under the electric equipment cover and, after the electric equipment cover has been removed, can be read through the window on the lower side of the chain hoist (illustra‐ tion differs from scope of delivery).

The 7-segment display is supplied as standard for:

● DC-Com 1 - 5 manufactured from 2007

● DC-Com 10

The following data can be read:

●

Software version  Fig. 8, Page 30,

●

Operating hours  Fig. 9, Page 30,

●

Operating statuses  "Operating statuses/general messages", Page 97,

●

Warning messages  "Warning messages", Page 98,

●

Error messages  "Error messages", Page 99.

4.4.3 Display of software version, operating hours, number of cycles

Display of software version

Fig. 8 Example: Software version 1.01

The software version is displayed every time power is switched on or after an emergency-stop (from software ver‐ sion 1.01).

Display of operating hours

Fig. 9 Example: 123 hours of operation

The display appears after 3 seconds without any lifting motion. If the control board has to be replaced, we recommend, if technically possible, that the details for the number of operating hours be read off and documented in the test and inspection booklet. The elapsed operating time coun‐ ter starts at "zero" if a replacement control board is installed.

Display of the number of cycles of the K1 contactor

Fig. 10 Example: C 15 corresponds to 15 x 100000 = 1,5 m K1 switching cycles

The display alternates between showing this information and the number of hours of operation. C 5 corresponds to 5 x 100000 = 500000 K1 switching cycles

For preventive maintenance, see  "Service life of the contactor", Page 64

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4.5 Central service enclosure

Fig. 11

All important service work can be carried out at a central point, the service enclosure. The relevant connectors for power supply, control pendant and travel drive are arranged under the impact-resistant plastic cover. The chain is also lubricated from this point. In addition, any control cable length that is not required is kept under the cover. The plastic cover also provides mechanical protection for the components fitted under it. The functions are indica‐ ted by pictograms fitted on the outside of the service cover.

4.6 Control pendant/control cable height adjustment

The control cable is protected by a flexible, easily bent strain relief hose. Its suspension height can be specifically adapted to the requirements at the workplace at any time by means of an adjusting mechanism. To do this, it is not necessary to cut the cable conductors or to shorten the strain relief hose. The length of control cable that is not needed is stored under the service cover. The strain relief hose is fixed at the selected suspension height by means of a self-locking clamp mechanism. The control pendant can be adjusted to a different suspension height by unlocking the clamp mechanism. The strain relief hose for the control pendant consists of an abrasion-resistant fabric hose with flame-protection impregnation. The control cable is reinforced by means of elastic rubber filler material in the gripping area (0,8) of the strain relief hose.

4.7 Control pendant

DSC control pendants (lifting/lowering) or DSE-10C control pendants (2 to 3 axes) must be used for manual ca‐ ble-connected control of the chain hoist. Both control pendants feature the same plug-in connection for the control cable. The control cable and the control pendant are connected by means of a bayonet lock. The shock and impact-resistant DSC and DSE-10C housings are of made high-quality thermoplastic and are re‐ sistant to fuels, salt water, greases, oils and alcaline solutions; IP65 enclosure. Strong mineral (e.g. hydrochloric or sulphuric) acids may, however, corrode pendant switch housings. To avoid this, they must be replaced in good time. The rubber button caps may be subject to premature wear under aggressive operating conditions (contact with corrosive substances or special chemicals). Replace any damaged button caps in good time.

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5 Assembly

5.1 General

These assembly instructions enable the owner to install, re-install or replace the DC-Com unit himself. The owner must appoint a coordinator who is authorised to issue instructions before assembly work commences.

Despite detailed information, errors cannot be excluded when the installation is assembled by the customer. For this reason, we recommend that this work be carried out by our trained specialists or by persons authorised by us.

The wiring of the Demag chain hoist complies in all respects with current DIN VDE and accident prevention regu‐ lations. Unauthorised intervention and modifications eliminate compliance with these regulations.

DANGER

Live components

Danger to life and limb.

It must be possible to switch off the power supply by means of a device to disconnect the power supply (e.g. mains connection or isolating switch with a padlock).

The chain hoists are supplied with power from an AC power network. The voltage and frequency of the AC pow‐ er network must match the data specified on the rating plate of the chain hoist.

5.2 Safety instructions for assembly

DANGER

Incorrect assembly

Danger to life and limb.

Incorrect installation may result in severe injury and/or damage to property. Therefore, this work may only be carried out by authorised, instructed personnel who are familiar with the principle of operation of the machine in compliance with all safety regulations.

– Ensure sufficient working clearance before starting assembly work.

– Secure and fence off the working and danger zone.

– If an elevating work platform is used for assembly, only use appropriate attachments for the lifting of per‐

sons which ensure that work is carried out in a safe and stable position.

– Only suitable, tested and calibrated tools and accessories may be used for assembly or disassembly work.

– Wear protective equipment.

– Be careful when working on open components that have sharp edges. Risk of injury.

– Keep the working area clean and tidy. Store any unneeded machine or installation parts and tools in such a

way that there is no risk of them falling.

– Fit components correctly and as intended. Comply with specified bolt tightening torques. Incorrectly fitted

components may fall and cause severe injuries.

– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐

ments must be fulfilled. The electrode holder and earth must be connected to the same assembly when welding work is carried out. Serious damage may otherwise be caused to the hoist.

– Customer-specific regulations must be observed.

DANGER

Live components

Danger to life and limb.

Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐ nel", Page 10) in compliance with the safety regulations.

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Switch off the electric power supply before starting work. The mains connection or isolating switch must be pro‐ tected against unauthorised or accidental restoration of the power supply by means of a padlock.

Mechanical safety All bolted connections must be correctly tightened. Self-locking nuts must not be replaced by other types of nut. Self-locking nuts must be replaced when they have been tightened and untightened five times. The clamping torque of a self-locking nut must not be lower than the loosening torque specified by EN ISO 2320. A sufficiently secure connection can only be guaranteed by tightening to the specified tightening torque. Bolted connections must not be lubricated as otherwise the specified tightening torque values will be too high. Check to ensure that pin connections are correctly fitted. All installation and assembly work must be completed in accordance with the operating instructions and the hoist chain must be greased. Operation with defective or damaged chains results in a high risk of accidents with per‐ sonal injuries and damage to the chain hoist and is therefore prohibited. Any change or modification which prejudices safety must be reported to the nearest person responsible immedi‐ ately. Repairs may only be carried out by experienced technicians. Ensure that all attachment points are freely accessible for inspections and servicing or that free access can be provided. The control device (e.g. control pendant) must be marked in such a way that the direction of movement is clear and distinct. The arrow symbol on the switching elements must correspond to the direction of movement.

Electric safety The chain hoist operating instructions must be referred to when Demag chain hoists are used. These operating instructions only contain standard circuit diagrams. Depending on the chain hoist type, an orderspecific circuit diagram may apply.

Protective earth conductor The protective earth conductor in insulated leads and cables must be coloured green and yellow along its entire length. The protective earth conductor must not be connected to mounting bolts or screws. Earth junctions and connections must be protected against accidental loosening (e.g. by using serrated lock washers to DIN 6798). It must be possible to disconnect each individual connection. Protective earth conductors must not carry any current in normal operation. The same number of protective earth connection points must be provided as electric power infeed and outfeed points. Continuity of the PE conductor connection must be checked.

Mains connection switch A mains connection switch must always be provided for the mains power supply line to the machine. The mains connection switch must be arranged to disconnect all poles of your DC-Com chain hoist from the mains supply. Ensure that the mains connection switch is installed in an easily accessible position in the vicinity of your machine and that it is clearly marked.

Isolating switch If two or more lifting appliances are fed from a common supply line, each one should be provided with an isolating switch. This makes it possible to carry out maintenance work on individual units, without affecting operation of the rest of the system.

Power supply The power supply line/cable to be used depends on the motor size, see the "Hoist motor data" section.

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5.3 DC-Com chain hoist tightening torques

Tightening torques [Nm] DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10

Reeving 1/1 1/1 2/1

Motor 9,5 25,0

Fan cover 4,0

Gearbox seal 5,5

Brake 5,5

Operating limit switches - 3,0

Control set 3,0

Electric equipment cover 9,5

Service cover 5,5 7,5

Limit stop 4,0 4,3 7,4

Anchorage halves - 10,5

Guide plate 5,5

Hook assembly 6,8 9,5 25,0 -

Bottom block with external cut-off springs

Bottom block with internal cut-off springs

Control cable locking mechanism 11,0

Tab. 22

CAUTION

Loose connections

Loose connections are a danger to life and limb and a risk of damage to the machine.

Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists.

– Self-locking nuts must not be replaced by other types of nut.

Bottom block halves 52,0

Guide section halves 5,5

55,0

5.4 Installation procedure

Unpack and dispose of the packing material in an environmentally compatible way  "Transport, packing and storage", Page 25.

Check the delivery is complete  "Transport inspection", Page 25.

Connect the control pendant, if necessary  "Connecting the control pendant", Page 35.

Which suspension bracket is suitable for suspension?  "Suspending the chain hoist", Page 40.

Adjust the height of the control pendant  "Control pendant height adjustment", Page 37.

Connect to the power supply  "Mains connection", Page 42.

Set the lowest hook position, if necessary  "Adjusting the lower hook position", Page 52.

Carry out checks before putting the unit into operation for the first time  "Inspections before putting into service for the first time", Page 54.

The equipment is ready for operation  "Operation", Page 55.

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5.5 Connecting the control pendant

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Fig. 12

The control pendant is of plug-in design. The connector on the end of the control cable is locked in the bayonet sleeve and can be turned. If a connector is not locked, it can be pulled out and must be locked again by pressure.

Unless the chain hoist is supplied with the control pendant fitted, connect the DSC control pendant with the con‐ trol cable and lock the connection with the bayonet lock as follows:

1. Lift bend protection sleeve (1) on the control pendant off the two pins.

2. Then pull bend protection sleeve (1) off the control pendant.

3. Slide bend protection sleeve (1) onto the control cable. Plug the control cable into the control pendant and

turn the bayonet lock until it is locked. Ensure that

– groove (a) on the connector holder lines up with swivel lock (b) in the control pendant housing and

– that the two pins (c) on the control pendant housing line up with bayonet lock (d).

4. Slide bend protection sleeve (1) over the control pendant again. Pay attention to the positioning markers.

Press bend protection sleeve (1) firmly onto the control pendant.

The control pendant can be attached to the chain hoist or installed as a travelling unit, see  "Mobile control sys‐ tem", Page 38.

5.6 Control cable

5.6.1 Control cable technical data

Fig. 13

Item Designation

1 Hose pocket

2 Control cable retaining latch

3 Control cable retaining bolt, tightening torque 11 Nm

Hook path H4 H5 H8 H11

Cable lengths 0,8 m - 2,8 m 0,8 m - 3,8 m 3,8 m - 6,8 m 6,8 m - 9,8 m

Tab. 23

The control pendant is supplied with standard cable lengths. The height can be adjusted by 2 or 3 m. Longer control cable lengths can be provided, for example, by using a 2TY control cable and DST-C or DSE-C control pendants.

Ergonomic workplace.

● The suspension height can be adjusted by means of a self-locking mechanism at any time to suit individual re‐ quirements.

● Adjust the suspension height of the control pendant in such a way that the operating elements are arranged at elbow height to obtain an ergonomic operating position.

5.6.2 Handling the control cable

Fig. 14

Do not allow the control cable to be wound around the chain when lifting motions are performed.

Optional snag protection can be used for the upper part of the control cable.

Designation Order no.

Protective sleeve with fitting material 720 085 45

Tab. 24

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5.6.3 Control pendant height adjustment

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Fig. 15

x Control cable locking mechanism engaged

y Control cable locking mechanism released

1. Undo the screws of the service cover.

2. Open and disconnect the service cover.

3. Remove and open the bag with the control cable.

4. Take the control cable out of the bag.

5. Slide the latch of the control cable locking mechanism upwards and hold it in place. At the same time, pull the control cable until the correct height has been reached for the control pendant.

6. If the control pendant is positioned too low, pull on the control cable hose behind the service cover. Slide the latch of the control cable locking mechanism downwards and lock the retainer by a short, strong pull on the control cable above the control pendant.

7. Lay the remaining control cable in loops and store it in the bag. The bag must be located behind the edge of the chain collector box. Close the service cover (tightening torque = 5,5 Nm).

5.6.4 Mobile control system

Component parts

Item Designation comprising Order no.

1 11-pole + PE flat cable 720 139 45

Socket enclosure

2 Connector enclosure cpl.

3 Connector adapter cpl.

4 Cable collector 720 065 45

5 DSE-10C control pendant 773 352 45

6 Control cable locking mechanism -

Tab. 25

Mounting frame

VC-AMS8 pin insert

Flat cable union

Bayonet lock

VC-MP-1-R-M25 bush enclosure

VC-TR1/2M bush frame

VC-TFS8 socket insert

720 187 45

720 087 45

H4, H5, H8, H11 height-adjustable standard control cables are used to‐ gether with the cable collector.

Fig. 16

Fig. 17

X40 plug connector pin assignment

Signal Cond. PIN Cond. Signal

- - B4 B8 11 Reference potential (24 V)

PE PE B3 B7 - -

- - B2 B6 - -

Special 2 (horn) 8 B1 B5 10 Right

Left 4 A4 A8 7 Lowering

Lifting 3 A3 A7 9

Emergency stop 2 A2 A6 6 Reverse

Forwards 1 A1 A5 5 Special 1 (F1/F2)

Tab. 26

Control voltage

(24 V, STS)

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5.7 Suspending the chain hoist

5.7.1 Supporting structure

DANGER

Overload

Danger to life and limb if the supporting structure is overloaded.

The support superstructure must be designed for the maximum load caused by operation of the chain hoist when it is used as intended.

Hoist units that have a load capacity greater than or equal to 1000 kg must be provided with overload protection to DIN EN 14492-2.

DC-Com chain hoists are used with a slipping clutch which directly acts as overload protection. The slipping clutch must be adjusted according to the load capacity of the chain hoist. For information on adjustment, see "Friction force checking device" document  Tab. 3, Page 7.

According to DIN EN 14492-2, the force limitation factor for DC chain hoists with a load capacity equal to or great‐ er than 1000 kg is: ϕ

= 1,6

DAL

Specification of the supporting structure must allow for the static and dynamic forces that occur when the overload protection device is tripped.

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5.7.2 Suspension bracket

Fig. 18

1 DC-Com 1 - 5 suspension bracket opened

2 DC-Com 10 1/1 reeving

43215244.eps

3 DC-Com 10 2/1 reeving

a Spacer tube

WARNING

DANGER

Overload

Danger to life and limb if the components are overloaded.

– The suspension/support structure for the chain hoist must be designed to accommodate the loads.

Chain hoist may fall

Danger to life and limb and risk of damage.

Do not move the chain hoist or leave it unsupervised when the suspension bracket is open.

The chain hoist is delivered with the long suspension bracket fitted to the chain hoist. The short suspension brack‐ et can be ordered to achieve an improved C dimension.

Assembly:

1. Remove the retaining clip and pin on one side.

2. Attach the suspension bracket (DC 10 according to the reeving arrangement) to the superstructure/trolley.

3. Insert the pin through the suspension and the suspension bracket (and through additional spacer tube (a) for DC 10) and secure with the retaining clip.

Make sure that the suspension bracket is fitted to match the reeving arrangement of the chain hoist. The chain hoist will hang at an angle if the suspension bracket is installed incorrectly. Suspension of the chain hoist at an angle results in premature wear of the chain drive. If special fittings are installed on the chain hoist, make sure that they are counter-balanced.

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5.8 Mains connection

Fig. 19

Item Designation Item Designation Item Designation

Strain relief attachment

DC-Com 1 - 5

Strain relief attachment

DC-Com 10

3 Connector enclosure 6 Recess for flat cable

Tab. 27

1 Sealing sleeve 4 Mains connection

2 4-pole connector 5 Recess for round cable

The mains connection cable, the mains connection fuse links and any devices to disconnect and switch the po‐ werfeed must be available on site in order to connect the unit to the power supply. A 4-lead cable with a PE earth conductor which complies with the table in  "Hoist motor data", Page 20 is required for the power supply.

Please note that the length of the supply cable specified for a given cross-section must not be exceeded in order to avoid excessive voltage drop and malfunctions during start-up of the motor caused by undervoltage.

Connection to the electric supply

● First check to ensure that the voltage and frequency specified on the rating plate match your mains supply. Ensure that the mains connection cable is not connected to the power supply and secured against accidental restoration of the power supply.

● Remove the service cover to connect the supply cable.

● Use the mains connection set included in the delivery for the plug connection to the mains connection cable.

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● Cut sleeve (1) to match the shape of the mains cable.

● In the area marked 7 to 13 for round cable; in the area marked 18x7 to 20x8 for flat cable. The system is de‐ signed for cable cross-sections of 4x1,5 mm

or 4x2,5 mm2.

● Slide sleeve (1) onto the mains cable. Make sure sleeve (1) tightly encloses the cable for the specified enclo‐ sure requirements.

● Connect the mains cable on connector (2) to terminals L1, L2, L3 and to the PE. If required, use the wire end sleeves included in the delivery.

● Slide connector (2) into housing (3) until it latches and close housing (3) with sleeve (1).

● Then insert connector (2) into the control system until the housing (3) latches with the card bracket.

● Finally insert the mains cable into the opening in the gearbox housing and secure it with the strain relief clamp. For DC-Com 1 to 5 units, the strain relief clamp must be turned to match the shape of the cable depending on the cable type (flat or round cable).

● All housing parts must be securely latched to ensure the unit is sealed.

● Check continuity of the earth lead connection after the mains cable has been connected and before the chain hoist is put into operation.

● The mains connector must never be disconnected under load.

Phase sequence for connection to the AC power network The chain hoist is configured for connection to clockwise R-S-T phases. The lifting and lowering buttons corre‐ spond to the movements of the load hook if the R-S-T mains phases are connected to L1-L2-L3 in the specified sequence. Then check the direction of movement as described below. If the phase sequence of the connection cable is unknown, connection with the correct phases is established in this way.

WARNING

Checking the direction of movement The chain hoist must be connected to the power supply to check whether all phases are correctly connected. Switch on the power supply, unlock the emergency stop and actuate the "Lifting" pushbutton on the control pend‐ ant. The load hook must now move upwards.

Incorrect direction of movement

Danger to life and limb if the direction of movement is wrong.

– If the direction of movement is not correct, disconnect the power supply at the mains connection switch and

check to ensure that it is not live.

– Swap phases L2 and L3 of the supply cable at the mains connection switch.

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5.9 Circuit diagrams and control boards

5.9.1 DC-Com 1 - 10 solo hoist circuit diagram

Fig. 20

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Fig. 21

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Fig. 22

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5.9.2 Circuit diagram with E11 - E34 DC travel drive

For further circuit diagrams with E11 - E34 travel drives, see  Tab. 3, Page 7 E11-E34 DC travel drive assembly instructions (II).

For further information on E11 - E34 travel drives, see  Tab. 3, Page 7 E11-E34 DC travel drive assembly in‐ structions (I).

For further information on cross-travel limit switch part no. 716 663 45, see  Tab. 3, Page 7 E 11-E 34 DC travel drive assembly instructions (I).

5.9.3 Control board

214 802 44/291113

Fig. 23

Item Designation Terminal strip Function

1 Plug-and-socket con‐

nector

2 Plug-and-socket con‐

nector

3 Relay Fast/slow

4 Relay Lifting/lowering

5 Relay Lifting/lowering (from 2009)

X8 Motor

X6 Brake

Item Designation Terminal strip Function

6 Contactor On/off

7 Transformer

8 Plug-and-socket con‐

nector

9 Fork light barrier Pulse generator

10 IR transmitter diode IR interface

11 7-segment LED Multi-function display, e.g.: elapsed operating time counter, status indicator, error code

12 Plug-and-socket con‐

nector

13 Dummy plug X5 (Optional) trolley

14 Plug-and-socket con‐

nector

SN... Serial number Label with:

Tab. 28

X1 Line

display

X4 Lifting limit switch

X3 Control cable

- Serial no. "SN …"

- Modification version "MV …"

- Production date calendar week/year "**/**"

Fig. 24 Pin 1 (1)

RJ45

connec‐

tor

PIN Control cable X3 (14) Trolley X5 (13)

1 Special F1 Special F1

2 Crane forwards Crane forwards

3 Crane backwards Crane backwards

4 Emergency stop Emergency stop

5 Control pendant supply Control pendant supply

6 Lifting 24 V AC from chain hoist

7 Lowering Control pendant reference potential

8 Trolley right Trolley right

9 Trolley left Trolley left

10 Special F2 Special F2

Tab. 29

Function assignment

PIN Lifting limit switch X4 (12)

Lifting

Lowering

Tab. 30

Function assignment

Fig. 25 Pin 1 (1)

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5.10 Programming parameters with the control pendant

5.10.1 General

Parameters can be programmed to adapt the chain hoist to specific application requirements. The parameters can be programmed using the control pendant together with the 7-segment display on the underside of the chain hoist.

5.10.2 Meaning of the buttons

Fig. 26

1 "Lift" - Accept selection 2 "Lower" - Move to next parameter or se‐

Tab. 31

lection value

5.10.3 Meaning of the parameters

From software version SW 2.10, the following parameters can be programmed:

Display of parameter no. Parameter name Display of parameter value Remark

Default V1/V2

Default Control pendant is locked when several keys are actuated.

Priority is given to the first button that is pressed if the lifting and lowering buttons are actuated together.

Default Speed-dependent start-up

Tab. 32

2 Hoist only V2 speed

3 Lock the control pendant

Time-controlled start-up

(e.g. for tandem operation)

Y. V2

Y. Time-controlled start-up

3 "Emergency stop" - End parameter pro‐

gramming (changes are saved)

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5.10.4 Starting parameter programming mode

Fig. 27

1st step: Actuate emergency stop.

7-segment display: 8. 7-segment display: (displays a dot) 7-segment display: P.

Tab. 33

Fig. 28

4th step: "P." disappears after approx. 2 seconds. Press the "Lifting" button again and hold it down until "o." (for O.K.) is displayed.

7-segment display: o. 7-segment display: 0. → 1. ··· 9. 7-segment display:

Tab. 34

2nd step: Press and hold down the "Lifting" button and unlock emergency stop. Wait for approx. 10 seconds.

5th step: Release the button. Parameter programming mode is now active. When parameter programming mode has been activated, figures "0." to "9." are each succes‐ sively displayed for 2 seconds.

3rd step: When "P." is displayed, release the "Lifting" button.

6th step: Press the "Lowering" button to scroll through the menu items faster. Each figure represents a parameter, see  "Meaning of the parameters", Page 49.

214 802 44/291113

Fig. 29

7th step: Press the "Lifting" button to select the currently displayed parameter. The value selection menu for the parameter opens at the same time. The currently set values are symbolically displayed with the characters "A.", "b.", "C." etc. For the meaning of the characters, see  "Meaning of the parameters", Page 49.

7-segment display: A. b. C. 7-segment display: 7-segment display:

Tab. 35

Fig. 30

8th step: To set a different value, press the "Lowering" button until the required value is shown in the display.

10th step: The unit returns to normal operating mode when the "Emergency stop" button is pressed. All changes are first saved.

7-segment display:

Tab. 36

9th step: The value is again selected by using the "Lift‐ ing" button, the system then also returns to pa‐ rameter selection mode.

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5.11 Adjusting the lower hook position

Fig. 31

Item Designation Item Designation

1 Buffer (limit switch option) 4 Limit stop

2 Damping plate 5 Unloaded chain fall

3 Buffer plate

Tab. 37

Ensure that the hook assembly touches the ground in the lower hook position when determining the hook path/ lifting height. The chain hoists are provided with a hook path of 4 m, 5 m or 8 m as standard.

Secure the limit stop to the 5th link at the dead (unloaded) end of the chain.

●

Follow the order of assembly. See also  "Buffer arrangement", Page 87

Tightening torques [Nm] DC 1 DC 2 DC 5 DC 10

Limit stop 4,0 4,3

Tab. 38

To reduce the hook path, proceed as follows:

1. Position the hook as shown in the diagram.

2. Stop the chain hoist by actuating the emergency stop or the mains connection switch and secure it against switching on again.

Remove the chain collector box  "Removing the chain collector box", Page 71.

4. Remove the limit stop on the chain collector box end.

5. Attach the limit stop directly behind the damping plate The unloaded chain fall behind the limit stop must con‐ sist of at least 5 chain links.

6. Place the chain in the collector box and re-connect it to the chain hoist.

7. Switch the chain hoist on and check adjustment of the lower hook position by moving the hook and run the chain once through over entire adjusted hook path.

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6 Putting into service for the first time

6.1 Safety instructions when putting into service for the first time

The machine may only be handed over when its safety has been verified by means of a corresponding check  "Checks on entering service, handover", Page 54.

WARNING

Safe operation of the machine is not yet ensured when it is first put into operation.

Machines may only be put into service if they have been installed/assembled according to the assembly instruc‐ tions.

– Machines may only be put into operation by qualified personnel.

– Check installation/operation of the safety devices before commissioning.

– Check to ensure that the mains voltage and frequency match the details specified on the rating plate.

– Move the trolleys by hand and check that they can be moved without resistance by hand over the entire

length of the track section (if fitted).

– Ensure sufficient working clearance before starting assembly work.

– Secure and fence off the working and danger zone.

– Wear protective equipment.

Only trained personnel may be employed when the installation is first put into operation since:

● it may be necessary to render safety devices or features inoperative when adjustments or function checks are carried out,

● work may need to be performed in the danger zone when the installation is first put into operation.

6.2 Inspection regulations

WARNING

Non-compliance with operating and maintenance regulations

Danger to life and limb.

Compliance with all inspection regulations is an essential aspect of ensuring safe operation of the machine.

Required tests and inspections must be carried out.

All inspections must be arranged and documented by the owner at the specified intervals/points of time.

– Inspection in accordance with relevant national regulations, e.g. UVV/BGV D6 for cranes; UVV/BGV D8 for

winches, hoists and towing devices in Germany.

The owner is responsible for ensuring that power-driven chain hoists are inspected by an expert engineer before they are first put into service and before they are put into service again after major modifications have been carried out. This also applies to manually operated or semi-powered chain hoists that have a load capacity of more than 1000 kg.

– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐

cerning the replacement of parts/assemblies prescribed in the operating instructions must be observed.

–

Please refer to  "Noise emission/sound pressure level", Page 25 for sound pressure level measurement values to DIN 45 635.

This work may only be carried out by specialist personnel.

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6.3 Inspections before putting into service for the first time

The owner is obliged to carry out the following checks before the unit is put into operation for the first time:

Activity Section Check

Check continuity of the PE conductor connection - X

Check emergency-stop device -X

Check direction of movement

Check 7-segment display

Check chain lubrication (under arduous conditions, the chain must be lubricated more frequently)

Check function of the lifting motion operating limit switch

Check function of the lowering motion operating limit switch

Check cut-off buffer/cut-off spring/operating limit switch actuator

Check control cable and control pendant housing for damage - X

Check operation of the brake -X

Check hook and hook safety catch

Tab. 39

 "7-segment display for operating status and fault display",

 "Display of software version, operating hours, number of cy‐

 "Checking the cut-off buffers/cut-off springs", Page 86,

 "Checking the operating limit switch actuator", Page 72

 "Mains connection", Page 42

Page 29,

cles", Page 30

 "Available hoist chains", Page 77

 "Checking operating limit switches", Page 71

 "Checking the load hook", Page 83

6.4 Checks on entering service, handover

WARNING

Unauthorised operation

Danger to life and limb if the machine is operated without previous inspection.

Machines may only be put into service if they have been checked for compliance with the corresponding acci‐ dent prevention regulations.

By means of suitable measures carried out by the owner or on his behalf, the owner must ensure that the load handling attachments and machinery ready for operation function in complete safety before they are first put into service. The specified measures must allow for the static and dynamic features of the machinery.

The following checks must be carried out when the installation enters service:

● The supporting structure must be in good condition and the load capacity of the chain hoist must be checked.

● Safety devices must be complete and effective.

● Clearances and safety distances must be maintained.

● The emergency-stop device must be checked by actuating the emergency stop.

When the unit is first put into operation, it must be checked to ensure that it is used as intended in all possible applications, in each case with the maximum permissible load. Operation of the safety devices must be checked (e.g. by lifting an overload). At the same time, the behaviour of the chain hoist must be checked when it is not used correctly.

Various checks of the machine must be carried out before it is handed over:

● Check to ensure it is suitable for operation

● Acceptance inspection

The test and inspection records can be compiled as soon as safe operation of the chain hoist is ensured. The test and inspection records (test and inspection booklet; observe relevant national regulations) must be hand‐ ed over when the machine is handed over. The machine may be used as intended after it has been handed over.

214 802 44/291113

7 Operation

7.1 Safety instructions for operation

WARNING

Incorrect operation

Risk of injury due to incorrect operation.

Incorrect operation may result in severe injury or damage to property. The equipment may only be operated by authorised and instructed personnel in compliance with all accident-prevention and safety regulations. National regulations for the use of cranes and lifting appliances must be observed and followed.

– The owner must arrange for operating personnel to be trained.

WARNING

Crushing hazard

There is a risk of injury due to parts of the body being crushed/sheared or clothing or hair becoming entangled when loads are lifted or lowered.

– Do not touch the chain.

– Do not reach between the upper and lower chain entry point.

– Do not reach into the area of the Manulift coupling when the quick-release coupling is connected.

– Do not reach between the load hook opening and the load handling attachment when loads are lifted.

– There must be nobody present in the immediate danger zone when the load is set down.

WARNING

Risk of burns

There is a risk of burns from contact when the chain hoist is in operation.

Do not touch hot motor housings.

Suspended load. Falling parts.

Danger to life and limb if lifted loads are dropped.

Keep out of the danger zone at all times

– Keep a sufficient safety distance.

– Never step under a suspended load.

– Loads must not be lifted above persons.

– Wear protective equipment.

Non-compliance with operating regulations/industrial safety regulations

Danger to life and limb if relevant regulations are disregarded.

Machinery may only be operated in compliance with relevant national operating regulations, e.g. BGV D6 for cranes in Germany.

– If required, apply a copy of the relevant operating regulations, part no. 214 748 44, at a suitable place

where operators can read them at any time (e.g. at the mains connection switch).

214 802 44/291113

The machine must not be put into operation or must be taken out of service immediately if any defects or irregu‐ larities relating to operating safety and reliability or functions are detected. Safety devices must not be rendered inoperative or modified contrary to their intended use.

Ensuring safe operation Special local conditions or special applications may lead to situations which were not known when this chapter was written. In this case, the owner must ensure safe operation or take the machine out of service until measures for safe operation have been clarified and implemented in agreement with Demag or other relevant bodies. In the event of a stoppage (e.g. if defects regarding safe and reliable operation are detected, in emergency situa‐ tions, in the event of operating malfunctions, for repairs and maintenance purposes, if damage is detected or after finishing work), the operator must carry out all prescribed safety measures or observe that they are automatically carried out. Work on electric equipment may only be carried out by qualified electricians.

7.2 Switching on

7.2.1 Checks when starting work

Before starting work, the operator must be satisfied that the machine is in safe and correct operating condition. Ensure that nobody is endangered by operation of the machine before it is switched on or put into operation. If the operator notices persons who may be exposed to a risk to their health or personal safety by operation of the in‐ stallation, he must stop operation immediately and may not resume operation until the persons are outside the danger zone.

The chain hoist must be taken out of service without delay if there are any defects which endanger safe and relia‐ ble operation. Defects relevant to safety in this sense are, for example:

● Damage to electric devices, cables or insulation,

● Delayed operation or failure of brakes and safety devices,

● Missing covers or housing parts or

● Damage to the chain or to supporting parts.

Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay. This also applies if damage occurs to parts of machinery or equipment which makes an immediate stoppage nec‐ essary. If the chain hoist has been stopped by an emergency stop due to safety-related defects, it must be secured against being returned to operation until an experienced technician is satisfied that the cause of the hazard situa‐ tion has been eliminated and that operation of the machine is possible without any hazard.

Before starting work:

● Wear protective equipment.

● Ensure that nobody is present in the danger zone of the equipment.

7.2.2 Function checks

Instructions for users where the BGV D06 accident prevention regulations apply: In accordance with BGV D06, the crane operator must also check operation of the emergency-stop device when he or she starts work. This does not apply to slipping clutches used as an emergency-stop device which do not need to be checked when work begins (BGV D06, Section 30). DC chain hoists are fitted with a slipping clutch as an emergency-stop device which does not need to be checked by the crane operator, therefore a device to bypass the limit switches which are approached during normal operation is not fitted. The following main functions of the machine must be checked before work begins:

Activity Section Check

Check emergency-stop device -X

Check 7-segment display

Check chain lubrication (under arduous conditions, the chain must be lubricated more fre‐ quently)

Check function of the lifting motion operating limit switch

Check cut-off buffer/cut-off spring/operating limit switch actuator

Check control cable and control pendant housing for damage - X

Check operation of the brake -X

Check hook and hook safety catch

Tab. 40

 "7-segment display for operating status and fault

display", Page 29,

 "Display of software version, operating hours, num‐

ber of cycles", Page 30

 "Available hoist chains", Page 77

 "Checking operating limit switches", Page 71

 "Checking the cut-off buffers/cut-off springs",

Page 86

 "Checking the load hook", Page 83

214 802 44/291113

7.3 Operation

7.3.1 Safety during operation

DANGER

Danger of broken chain and falling load

The chain may break and loads may fall if the emergency limit position limiter is frequently approached.

The chain hoist slipping clutch provides the emergency limit position limiter function for chain hoists that are not fitted with an operating limit switch or which have a defective operating limit switch. This emergency limit position limiter may only be approached in exceptional cases, i.e. it must not be approached in normal operation. High additional loads occur in the chain when the slipping clutch is tripped.

For this reason, the "operating limit switch for lifting" function must be checked every day.

WARNING

Overload

Danger to life and limb.

Higher loads than those specified on the load capacity plate must not be handled.

– Do not exceed the maximum permissible load capacity of the hoist.

– Only use load handling attachments which are adequately dimensioned.

– Only use load handling attachments for their intended purpose.

WARNING

Movable parts may start moving.

Danger to life and limb.

The control pendant is designed to be suspended from its connecting cable. It may only be used as suspended equipment. It must not be deposited in/on transport containers, workbenches, etc., or in any other way.

Important information for operation Observe the following during operation:

– Take the machine out of service immediately if functional defects or irregularities are detected.

– The operator is obliged to check the machine for any visible damage at least once per shift and to report any

damage immediately.

– Do not render safety devices inoperative.

– Do not approach limit stops in normal operation, e.g.: emergency-stop devices (emergency limit switches),

emergency limit stop devices (slipping clutch or emergency limit switch), track and limit buffers to stop move‐ ment of the crab or crane, hook assembly or bottom block against limit stops. Continuously approaching these limits may result in severe damage and may even break the hoist chain.

– Pay attention to all regulations regarding the correct loading of chains.

– Do not reach into rotating parts and maintain a sufficient safety distance to prevent clothing, parts of the

body or hair becoming entangled.

7.3.2 Load pick-up

214 802 44/291113

– The load handling attachment and load must be flexibly suspended. Rigid connections cause uncontrolled

forces to be transmitted and lead to fatigue fracture. To protect the chain from unwanted torsion when the load turns, movement of the hook assembly/bottom block must not be restricted.

– The bottom block must not be twisted or turned over for 2/1 reeving arrangements; chain links facing the

same direction must be arranged opposite each other without being twisted.

– When attaching the load, ensure that the load or load attachment does not slip off the hook and that the load

does not fall over, fall apart, slip or roll off when it is picked up or set down.

– When the load is lifted, the hook must move to an upright position to ensure that the safety catch is not sub‐

jected to a load by the load handling slings and, as a result, damaged.

– Do not use the equipment to transport persons.

– The load capacity specified on the load capacity plate indicates the highest permissible load, which must not

be exceeded. This is the sum of the load to be lifted and the load handling attachment. Only approved load handling attachments may be used. The load capacity of the load handling attachment must not be excee‐ ded.

7.3.3 Moving the load

– For lifting and travel motions, adopt a position that provides a clear view of the danger zone or use a second

person who can observe the danger zone.

– Push-travel hoists/trolleys/cranes may only be moved by pulling or pushing the load, bottom block or load

hook assembly. Never pull on the control pendant.

– Push-travel loads must be guided by hand. The load must never be thrown or hurled.

– Do not handle suspended loads above persons.

– Do not pull or drag suspended loads at an angle. The chain drive mechanism may be damaged at angles of

4° or more.

– Do not pull free fixed or obstructed loads with the chain hoist.

– Do not leave suspended loads unsupervised.

– Do not allow the chain to pass over edges and do not use the chain as a load bearing sling.

– Do not allow loads to drop when the chain is in a slack condition.

– Vibration from the load being transported (e.g. when the load is deposited on vibrating machinery) must not

be transmitted to the lifting equipment.

– Chain hoists must be suspended in such a way that they do not collide with stationary equipment and struc‐

tures, e.g. when slewing cranes are turned.

– Do not pick the load up at full speed.

– Avoid inching (e.g. giving short pulses to the motor).

7.3.4 Load distribution

CAUTION

Premature wear of the chain guide and chain.

Danger of falling load.

Avoid uneven loads on the chain falls. This results in dam‐ age to the chain guide and causes the chain to break.

Blocked chains or large play between the chain and the chain sprocket will destroy the chain guide.

– Eliminate any knots or blockages in the chain before

lifting/lowering.

Fig. 32

214 802 44/291113

7.3.5 Emergency-stop device operating function

When the emergency stop is actuated, the hoist motor is immediately disconnected from the electric power sup‐ ply, the mechanical brake is applied and it brings any movement to standstill. Operation can only be resumed by unlatching the emergency stop when no lifting or lowering commands are ap‐ plied (off-position interlock). The effectiveness of the emergency-stop function depends on the good operating condition of the mechanical brake. Unusually long braking distances may indicate excessive wear of the brake. In this case, the brake must be inspected by an experienced technician without delay.

7.3.6 Slipping clutch operating function

The chain hoist is fitted with a slipping clutch that is tripped if an overload occurs. The brake is then automatically applied and the motor is switched off. Only lowering motion remains possible after the slipping clutch has tripped. Therefore, an overload cannot be lifted from the ground. A load that is already suspended can be safely deposited by actuating the lowering button. When the lowering motion has been completed, lifting is possible again. If the slipping clutch already trips at rated load, the slipping force must be measured by an experienced technician and re-adjusted, as required.

7.3.7 Lifting path limiter operating function

Only motion in the opposite direction remains possible after the lifting path limiter has tripped. The lifting path is limited by limit stops at the ends of the chain. Consequently, the slipping clutch acts as an emergency-stop de‐ vice, the brake is automatically applied and the motor is switched off. A warning message is shown on the display if the emergency-stop device is tripped. Operating limit switch contacts prevent travel against the emergency limit stop device; they are actuated by elastic buffers on the limit stop and switch the motion off before the emergency limit stop device is reached. The emergency limit stop device must not be tripped by DC-Com chain hoists that are not fitted with operating limit switches.

7.4 Emergency stop

214 802 44/291113

Fig. 33 Position of the emergency stop (1), DC-Com not in connection with DSM-C

WARNING

Unauthorised, negligent or accidental switching-on.

Danger to life and limb.

Check to ensure that the reason for the emergency stop has been eliminated before the machine is switched on again.

The emergency-stop device must not be used to switch the machine off in normal operation.

Every chain hoist is fitted with an emergency-stop device with which all motions can be stopped in the event of a hazard.

The emergency-stop button is arranged in a clearly visible position on the control pendant. Anybody who identifies an immediate danger of personal injury must actuate the emergency stop without delay. This also applies in the case of damage that occurs to parts of the machine and equipment which makes it necessary to stop and secure the machine immediately.

● To actuate the emergency stop, press the button until it reaches the end stop. It then locks automatically and the chain hoist is shut down.

● To unlock the actuated emergency stop, turn the pushbutton in the direction of the arrows (clockwise) and re‐ lease it.

Following an emergency stop, do not switch the machine on again until a trained person is satisfied that:

● the cause which led to actuation of this function has been rectified and

● continued operation of the machine constitutes no further hazard.

Control pendant

Demag chain hoists can be equipped with various control pendants, as required. Refer to the relevant documents for operation of the control pendant and button assignments, see  Tab. 3, Page 7.

7.5 Taking the equipment out of operation

7.5.1 Taking the equipment out of service when faults occur

The machine must be switched off immediately if the following faults occur:

● If electric devices and cables as well as parts of the insulation are damaged.

● Brake and safety device failure.

7.5.2 Taking the equipment out of service at the end of the shift

The following measures must be taken when finishing work or leaving the working area:

● Position the hoist unit outside the travel area.

● Move the unloaded hoist unit into its resting position.

● Actuate the emergency stop.

● Switch the hoist unit power supply off at the mains connection or isolating switch.

The chain hoist must be disconnected from the power supply when finishing work or leaving the working area. However, if the chain hoist is continuously connected to the power supply, the following must be considered:

● The chain hoist is not protected against unauthorised or accidental switching-on and, therefore, it is not pro‐ tected against unintended movements.

● Damage may be caused by an electric surge if lightning strikes.

● The power-supply line and the electric cabling and wiring must be checked with particular care and at shorter intervals.

● The control system of the chain hoist consumes approx. 1,1 VA when at standstill.

7.5.3 Taking the equipment out of service for maintenance and repairs

1. Switch off the mains connection switch or isolating switch before commencing maintenance work.

214 802 44/291113

2. Secure the mains connection switch with a padlock to prevent unauthorised or accidental reconnection to the supply.

3. Only carry out maintenance work on the chain hoist when the load has been removed.

4. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.

5. Observe the relevant accident prevention regulations, instructions concerning intended use and statutory regulations for operation and maintenance.

6. Observe relevant safety regulations when repairing electric equipment.

214 802 44/291113

8 Maintenance/repair

8.1 Safety instructions for maintenance and repair work

The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted operation of the equipment.

DANGER

Live components

Danger to life and limb.

Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐ nel", Page 10) in compliance with the safety regulations.

WARNING

Risk of burns

Risk of burns from contact after the chain hoist has been in operation.

Do not touch hot motor housings. Allow the motor to cool down before performing any maintenance or repair work.

WARNING

Inappropriate maintenance work

Danger to life and limb. Risk of material damage.

Maintenance and repair work may only be carried out by authorised, instructed personnel ( "Definition of per‐ sonnel", Page 10) in compliance with the safety regulations.

– Secure and fence off the working and danger zone.

– If an elevating work platform is used for maintenance work, only use appropriate attachments for the lifting

of persons which ensure that work is carried out in a safe and stable position.

– Only suitable, tested and calibrated tools and accessories may be used for maintenance work.

–

Only use approved spare parts, see also  "Use of spare parts", Page 9.

– Wear protective equipment.

– Be careful when working on open components that have sharp edges. Risk of injury.

– Keep the working area clean and tidy. Store any unneeded machine or installation parts and tools in such a

way that there is no risk of them falling.

– Fit components correctly and as intended. Comply with specified bolt tightening torques. Incorrectly fitted

components may fall and cause severe injuries.

– Welding work may only be carried out by persons who are specially qualified. DIN welding work require‐

ments must be fulfilled. The electrode holder and earth must be connected to the same assembly when welding work is carried out. Otherwise serious damage may be caused to the hoist. Trolleys must not be welded or drilled.

– Customer-specific regulations must be observed.

CAUTION

Loose connections

Loose connections are a danger to life and limb and a risk of damage to the machine.

Metal nuts featuring a locking element (self-locking nuts) are mainly used for Demag chain hoists.

– Self-locking nuts must not be replaced by other types of nut.

214 802 44/291113

CAUTION

Risk of injury.

Oils and lubricants may pose a health hazard.

Contact with these media may result in serious damage to health (poisoning, allergies, skin irritations, etc.).

CAUTION

Risk of injury.

Leaking oils and lubricants are hazards due to the increased risk of slipping.

Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in an environmentally compatible way.

8.2 Basic maintenance requirements

General information on maintenance/repairs

The specified inspection and maintenance intervals ( "Maintenance schedule", Page 68) apply to normal chain hoist operating conditions. All wearing parts must be checked in the course of the annual inspection.

If routine maintenance reveals that the intervals are too long, they should be adapted to the specific operating conditions.

Electric components Only fuse links with the specified amperage and tripping characteristics may be used in the electric circuits. De‐ fective fuse links must not be bridged.

Pay attention to the following when working on machinery or machine equipment:

1. Wear personal protection equipment.

2. Before starting any maintenance work, switch off the mains connection switch and protect it against unau‐ thorised or accidental reconnection to the power supply by locking it with a padlock.

3. Ensure that the chain hoist is switched off, checked that it is de-energised and, in special cases, isolated.

4. Only carry out maintenance work on the chain hoist when the load has been removed.

5. Ensure that there is sufficient freedom of movement. Keep the working area clean and tidy. Loose parts or tools left lying around may cause accidents.

6. Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out.

7. Observe the relevant accident prevention regulations, instructions concerning appropriate use and statutory regulations for operation and maintenance.

8. Observe the relevant safety regulations when repairing electric equipment.

9. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐ ing maintenance work.

Maintenance work which is not possible from the ground may only be carried out from work stands or platforms. The danger zone below the chain hoist must be fenced off if there is a risk of falling objects.

Instructions for maintenance work in the course of operation If maintenance work has to be carried out on the chain hoist in the course of operation, special safety precautions must be taken depending on the operating situation. In each individual case, the owner or the person assigned by him must check whether the maintenance work may be carried out in the course of operation without risk of per‐ sonal injury and, taking into account the local conditions, must implement all necessary safety precautions. Replace damaged or deformed spring clip fasteners and split sleeves. Defective bolted connections must be replaced. Ensure that operating and auxiliary materials and replaced parts are disposed of in an environmentally friendly manner.

214 802 44/291113

After finishing maintenance work

Re-install safety devices as required by relevant regulations and check them for correct operation after finishing maintenance work.

Carry out a test run at partial load after the chain hoist has been fully re-assembled. Ensure that the chain runs smoothly during the test run.

8.3 Regular inspections

8.3.1 Required tests and inspections

WARNING

Non-compliance with operating and maintenance regulations

Danger to life and limb.

Required tests and inspections must be carried out.

– An annual inspection, e.g. as specified in German accident prevention regulations UVV/BGV D8 Sec‐

tion 23 (2) and BGV D6 (1) must be carried out.

– Adjustment, maintenance and inspection activities and inspection deadlines including specifications con‐

cerning the replacement of parts/assemblies prescribed in the operating instructions must be observed.

This work may only be carried out by specialist personnel.

Hoists and cranes must be inspected by an experienced technician at least once a year. Regular inspections mainly consist of a visual inspection and a function check which should include a check to determine the condition of components and equipment regarding damage, wear, corrosion or other alterations and a check to determine the integrity and efficiency of safety devices. Regular inspections must be carried out in accordance with BGV D6 and BCG 905 "Principles for the inspection of cranes" in Germany. It may be necessary to remove parts in order to inspect wearing parts. Defective parts and components and parts close to failure must be replaced. Load-bearing media and suspensions must be inspected along their entire length, including those parts which cannot normally be seen. A function and brake test with a load (test load that is close to the maximum permissible load capacity) must be carried out.

Please also see  "S.W.P. measures for achieving safe working periods", Page 65 and  "Maintenance sched‐ ule", Page 68.

Updating the test and inspection booklet

● All inspections must be arranged and documented in the test and inspection booklet by the owner.

8.3.2 Special operating conditions

CAUTION

Premature wear of the chain.

Danger of falling load.

Special operating conditions or the design of the chain hoist may make it necessary shorten the maintenance and inspection intervals.

– If, for example, the unit always brakes heavily at the same position and with a heavy load, increased wear

may occur on the chain links that are in the area of the chain or return sprocket when the brake is applied.

8.3.3 Service life of the contactor

The switchgear is subject to wear when the chain hoist is operated. Its service life has been rated for the specified loading group. Premature wear may occur if the equipment is frequently started and stopped.

214 802 44/291113

DC chain hoist

28060

5ZNK 80 60 50

10 ZNK 100 A 50 20

10 ZNK 100 B 20 -

Tab. 41

Motor size Display value C for U

ZNK 71

Display value C specifies the expected service life of the contactor multiplied by 100000. This value was deter‐ mined under normal operating conditions. For other conditions, the service life of the contactor may be shorter or longer,  "Display of software version, operating hours, number of cycles", Page 30.

We recommend that the contactor or the control module be replaced when the relevant display value has been reached,  "Replacing the contactor on the control board", Page 92.

8.3.4 S.W.P. measures for achieving safe working periods

8.3.4.1 General

The safety and health provisions of the EC Machinery Directive make it a legal requirement to eliminate special hazards which may be caused, for example, by fatigue and ageing. This requirement is also reflected in the third supplement to German accident prevention regulations UVV/ BGV D8 of 1.4.1996. This requirement obliges the owner of serial hoist units to determine the actual duration of service of the chain hoist on the basis of the operating hours, load spectra and/or recording factors. This is based on FEM 9.755/06.1993 Measures for achieving safe working periods for powered serial hoist units (S.W.P.). The objective of this rule is to determine measures for achieving safe working periods over the entire duration of service, although, according to the state-of-the-art, the chain hoists are designed for specific periods of operation. Premature failure cannot, however, be ruled out.

380 - 575 V Display value C for U

nom

80 80

220 - 240 V

nom

The following items have been taken from FEM rule 9.755 with reference to the electric chain hoist:

1. The actual duration of service determined on the basis of operating time and load must be documented at least once per year.

2. Operating time T

3. Load k

(load spectrum) must be estimated.

4. The value determined for operating time T

(number of operating hours) can be estimated or read on an elapsed time indicator.

using an elapsed time indicator must be multiplied by the type of

recording factor f = 1,1.

5. The value determined for the estimated operating hours and load spectrum must be multiplied by the type of recording factor f = 1,2.

6. The actual duration of service S is calculated as: S = k

x Ti x f

7. A general overhaul must be carried out when the theoretical duration of service is reached.

8. All checks and inspections and the general overhaul must be arranged by the owner of the hoist unit.

A general overhaul is defined as:

Inspection of the machinery for the purpose of detecting all defective components and/or components and parts close to failure and the replacement of all such components and parts. Following a general overhaul, the machi‐ nery is in a condition similar to that of the same machinery in new condition as far as the principle of operation and performance values are concerned.

For electric chain hoists classified according to FEM 9.511, the following theoretical durations of service apply (converted into full load hours):

214 802 44/291113

Group of mechanisms 1Cm 1Bm 1Am 2m 2m+ 3m 4m

Duration of service/full load hours [h]

Tab. 42

200 400 800 1600 1900 3200 6300

The actual duration of service is considerably increased if the chain hoist is only operated with partial loads. For a hoist unit operated on average with half load, for example, this results in an 8-fold increase in the actual duration of service; with operation at one quarter of the full load, a 64-fold increase.

8.3.4.2 Calculating the actual duration of service S

The actual duration of service S of the electric chain hoist can be determined as follows: S = k

x Ti x f

: Actual load spectrum factor

: Number of operating hours

f : Factor depending on the type of recording

Calculating the number of hours of operation (operating time) T

(by the owner)

The operating time can be calculated by means of an elapsed time indicator or according to the following method: Operating time per inspection interval:

Ti =

Tab. 43

(lifting + lowering) x cycles/h x operating time/day x days/inspection interval

60 x lifting speed

Only lifting and lowering movements are counted, long and cross-travel times are not considered.

Estimating load spectrum factor k To simplify estimation, each type of load can be grouped together into k

(by the owner)

load spectrum modules. The types of

load are simplified and quoted as 1/4, 1/2, 3/4 load and full load. Dead loads are added to the loads. Loads up to 20% of the rated load capacity are not considered. The operating time for each type of load is divided up within the inspection interval (e.g. 1 year) in terms of per‐ centage. The following bar diagram shows the k

load spectrum modules for the load conditions without load up to full load

in time increments of 5 and 10%. Larger shares of the time period must be correspondingly added together. Load spectrum factor k

can be obtained by adding together the individual km load spectrum modules.

Diagram

Fig. 34

B Loading L Load t Time 1 Dead load

Tab. 44

Factor depending on the type of recording

● f = 1,1

For calculating the operating hours using an elapsed time indicator (included in the DC-Com standard scope of delivery).

● f = 1,2

For estimating the operating hours and the load spectrum.

8.3.4.3 Example: DC-Com 10-1000 1/1 H5 V4/1 in 1Am

Lifting speed 4/1 m/min

No. of cycles per hour 10 cycles/h

214 802 44/291113

Lifting and lowering (2+2) m/cycle = 4 m/cycle

Operating time per day 8 h/day

Days per inspection interval 250 days/inspection interval

Tab. 45

Calculation

Ti =

Tab. 46

10 • 4 • 8 • 250

60 • 4

With operating time read: 334 With estimated operating time: 333,3 In the operating time as read/estimated above, the chain hoist has transported the following loads:

Fig. 35

B Loading L Load t Time

Tab. 47

Adding the load spectrum modules km together results in the load spectrum factor kmi = 0,119

Thus, the actual duration of service amounts to S [h] = k

x Ti x f =

● With operating time read 0,119 x 334 x 1,1 = 43,72

● With estimated operating time 0,119 x 333,3 x 1,2 = 47,6

For classification in FEM group of mechanisms 1Am (see DC-Com data plate) with a theoretical duration of serv‐ ice of 800 hours (see table below) the hoist has a theoretical remaining duration of service of

● With operating time read 756,28 hours

● With estimated operating time 752,4 hours

Documentation: Enter these values in your test and inspection booklet or crane installation test and inspection booklet. This entry may appear as follows:

Date Operating hours Load [%] km factor Load spec‐

From To T

3.1.- 30.12.- Read 334

3.1.- 30.12.- Estimated 333,3

Tab. 48

value

[h]

full 3/4 1/2 1/4 none k

510 20 15 50

0,05 0,042 0,025 0,002 -

510 20 15 50

0,05 0,042 0,025 0,002 -

trum factor

0,119 1,1 43,72 800/1Am 756,28

0,119 1,2 47,6 800/1Am 752,4

Actual dura‐

tion of serv‐

ice

Use

[h]

Theoretical

duration of

service

D [h] Group

of mech.

Remaining

use

D - S

[h]

214 802 44/291113

8.3.5 GO general overhaul

The chain hoists are designed for a period of use of at least 10 years until the first general overhaul is carried out. This is based on the condition that the specified group of mechanisms is not exceeded by the actual dura‐ tion of service. When the actual duration of service has reached the theoretical duration of service relevant for the given group of mechanisms, further operation of the chain hoist is only permitted after a general overhaul has been carried out.

The theoretical duration of service D (hours at full load h) depends on the Group of Mechanisms classification of the chain hoist. The actual duration of service should be determined every year according to FEM 9.755. You can arrange to have the actual service life calculated as part of the annual inspection by our after-sales service. The owner must arrange for a GO general overhaul to be carried out when 90% of the theoretical duration of serv‐ ice has elapsed – if the chain hoists are correctly classified after 8 to 10 years. A general overhaul must be carried out by the end of the theoretical duration of service.

During the general overhaul, the following parts must be replaced in addition to the checks and work specified in the inspection and maintenance schedule:

● Gearbox housing with installed gear parts,

● Gear oil and gearbox cover with seal,

● Connecting elements,

● Shaft sealing rings, bearings, plugs,

●Brake.

The small parts (screws, washers, etc.) to be replaced when maintenance and assembly work is carried out are not listed separately. The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the requirement to be met for continued operation of the chain hoist. Therefore, the provisions of the relevant UVV accident prevention regulations and BGV D8 are satisfied. The equipment may continue to be used when an expert engineer has entered the conditions for further utilisation into the test and inspection booklet. Completion of the general overhaul must be confirmed in the test and inspec‐ tion booklet and a further period of utilisation in accordance with FEM 9.755 must be entered.

8.4 Maintenance schedule

Activity Section Before first put‐

Check continuity of the PE conductor connection - X

Check emergency-stop device - X X

Check direction of movement

Check 7-segment display

Check chain lubrication (under arduous conditions, the chain must be lubricated more frequently)

Check function of the lifting motion operating limit switch

Check function of the lowering motion operating limit switch

Check cut-off buffer/cut-off spring/operating limit switch actuator

Check control cable and control pendant housing for damage - X X X

Check operation of the brake - X X X

Check hook and hook safety catch

Check load handling attachments for deformation, cracks, damage caused by corrosion, safety device malfunctions

Read the C switching cycles

Read operating hours to determine the remaining safe working pe‐ riod

Check electric switchgear and wiring - X

 "Mains connection", Page 42

 "7-segment display for operating sta‐

tus and fault display", Page 29,

 "Display of software version, operating

hours, number of cycles", Page 30

 "Available hoist chains", Page 77

 "Checking operating limit switches",

Page 71

 "Checking operating limit switches",

Page 71

 "Checking the cut-off buffers/cut-off

springs", Page 86

 "Checking the operating limit switch

actuator", Page 72

 "Checking the load hook", Page 83

 "Service life of the contactor", Page 64

 "7-segment display for operating sta‐

tus and fault display", Page 29

 "S.W.P. measures for achieving safe

working periods", Page 65

ting into opera‐

tion

XXX

X X

XXX

Before starting

work

During the an‐

nual inspection

214 802 44/291113

Activity Section Before first put‐

ting into opera‐

Before starting

work

During the an‐

nual inspection

tion

Check operation of the slipping clutch

Check adjustment of the slipping clutch

Check brake wear

 "Checking the slipping clutch",

Page 90

 "Adjusting the slipping clutch",

Page 90

 "Brake", Page 88

Every 10 years

21) 22)

Grease brake V sealing ring X

Check suspension, suspension bracket and securing elements (clip, etc.)

 "Suspension", Page 70

Check fastening bolts on hook assembly/bottom block - X

Check hooks for cracks, deformation and wear

 "Checking the load hook", Page 83

Check hook safety catch for deformation - X

Check hook bearing for wear - X

Check rubber lip in the bottom block

 "Replacing the bottom block (stand‐ ard) with internal cut-off springs for 2/1

reeving", Page 85

Check sprocket of chain guide, chain sprocket of bottom block, chain guide, guide plate

 "Chain drive", Page 73

Check that the chain and chain collector box are properly secured - X

Check the chain for deformation, damage, cracks, pitting, reduc‐ tion in the thickness of the links or increase in pitch due to wear,

 "Checking the hoist chain", Page 74

elongation caused by deformation

Check securing elements (clips, bolts, etc.) for tight fit and corro‐ sion

Check and apply or supplement corrosion protection, as required - X

Check the electric enclosure and gearbox for leakage - X

Check trolley, crossbar and condition of buffers

Oil change

 "Checking the cut-off buffers/cut-off

springs", Page 86

 "Gearbox/oil change", Page 91

Every 10 years

22)

General overhaul

The general overhaul should coincide with the annual inspection. When 90% of the theoretical duration of service is

reached  "S.W.P. measures for achieving safe

working periods", Page 65

Fit chain hoist-specific Demag GO set X

The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not listed separately. The checks and work speci‐ fied in the inspection and maintenance schedule must be carried out during the general overhaul.

Tab. 49

214 802 44/291113

21)

DC 10 every 5 years

22)

For use according to FEM classification

8.5 Maintenance work

8.5.1 Suspension

If a check or inspection reveals that these components are worn beyond the specified dimensions or if cracks can be seen in these parts, they must be replaced at once.

Suspension bracket

Fig. 36

Suspension ring

Chain hoist DC 1 / 2 / 5 DC 10

Suspension bracket short long short long

Suspension bracket min. dimen‐ sion e

Tab. 50

Chain hoist DC 1 / 2 / 5 DC 10

Suspension ring turned 90° (chain hoist parallel to girder) min. dimen‐ sion e

Tab. 51

[mm] 15,3 14,4 25,2 24,3

[mm] 17,55 24,3

Fig. 37

8.5.2 Electric equipment cover

The electric equipment cover must be held in place when it is opened. Do not allow the electric equipment cover to fall against its retainer. When the electric equipment cover is closed again, ensure that the retainer does not snag and does not block the inspection window.

214 802 44/291113

8.5.3 Removing the chain collector box

Fig. 38

– Unscrew and remove service cover (1).

– Place bag (2) with the control cable on the top of the chain hoist.

– Disconnect spring (3) and place it in the recess in the chain collector box.

– Remove retaining spring (4) from pin (5) and remove the pin. While doing so, hold the chain collector.

– Place chain collector box (6) on the ground.

8.5.4 Operating limit switches (standard for DC-Com 10 with 2/1 reeving)

8.5.4.1 Checking operating limit switches

DANGER

Danger of broken chain and falling load

The chain may break and loads may fall if the emergency limit position limiter is frequently approached.

214 802 44/291113

For this reason, the "operating limit switch for lifting" function must be checked every day.

If an operating limit switch is defective, the hoist motor is switched off when the electronic speed monitoring func‐ tion of the slipping clutch is tripped. For this reason, cut-off in the upper hook position is not a reliable indicator for correct operation of the operating limit switch. If cut-off by the operating limit switch fails, a warning message is output, see  "Warning messages", Page 98.

Checking the operating limit switch for lifting: raise the hook assembly or bottom block until it is approximately 10 cm below the highest hook position. Then raise it to the highest hook position at creep lifting speed until the chain hoist automatically switches off.

● 1/1 reeving:

It must only be possible to compress the buffer or cut-off springs on the hook assembly by a small amount after the unit has switched off.

● 2/1 reeving:

It must only be possible to compress the upper part of a bottom block with internal cut-off springs onto the lower part by a small amount so that approx. 20 mm of the black part of the bottom block remains visible.

It must also only be possible to compress the springs on a bottom block with external cut-off springs by a small amount after the unit

Fig. 39 Buffer with limit switch not actuated (A), buffer with limit switch actuated (B), defective buffer with limit switch actuated (C).

has switched off.

If the buffer or cut-off springs are strongly compressed, it may be assumed that the hoist motor will not be switched off by the limit switch, but by the speed-monitoring function of the slipping clutch. This may cause the chain to break if the limit position is frequently approached.

Checking the operating limit switch for lowering

The "Operating limit switch for lowering" must be checked at least once per year.

Proceed as follows:

●

Remove the chain collector box  "Removing the chain collector box", Page 71

● Check as described above for the "Operating limit switch for lifting".

Optional geared limit switch If an optional geared limit switch is fitted, the hoist unit must be switched off before the bottom block or hook as‐ sembly come into contact with the chain hoist guide plate. To check this function, the upper hook position must be approached at high lifting speed (without a load). When the hoist unit has been switched off, there must be a mini‐ mum distance of at least 20 mm between the bottom block or hook assembly and the chain hoist guide plate.

8.5.4.2 Checking the operating limit switch actuator

The operating limit switch actuator must be checked for any external damage, e.g. a bent actuator plate.

214 802 44/291113

8.5.5 Chain drive

8.5.5.1 Checking the sprocket wheel

Fig. 40 Chain sprocket wear

8.5.5.2 Checking the chain guide

Since the chain sprocket is usually replaced together with the chain set, no further check is necessary under normal conditions. However, if you notice any uneven or harsh running in the chain drive mechanism, this may indicate wear.

The chain guide must be removed and degreased to enable the chain sprocket to be inspected properly. If the chain sprocket shows signs of wear from the chain or chipping on its sides, the chain set must be replaced without delay.

The chain drive can move easily on the drive shaft, i.e. lateral play of approx. ±2 mm is normal. A defective chain guide must be replaced im‐ mediately:

● Open the service cover.

● Check the chain guide for any damage, e.g. ruptured guide section halves or loose bolts.

214 802 44/291113

Fig. 41 Example of a defective chain guide

8.5.5.3 Checking the guide plate/chain entry plate

Maximum guide plate dimensions [mm] a b c d

DC 1 / 2 16,0 5,5 16,8 6,8

DC 5 19,4 6,8 21,0 8,9

DC 10 26,7 9,4 28,8 12,0

Tab. 52

If a check or inspection reveals that it is worn beyond the specified di‐ mensions or if cracks can be seen on the guide plate, it must be re‐ placed.

Multiple fitting and removal of the guide plate retaining bolts may dam‐ age the thread in the aluminium housing in such a way that a tight fit of the bolts can no longer be ensured. A "Guide plate accessories" set is available to do this (part no. 717 830 45), see also "DC 1 - 15 guide plate accessories" document  Tab. 3, Page 7.

Fig. 42 Load hook side (A), chain collector box side (B)

8.5.5.4 Checking the hoist chain

Checking wear or deformation of the original Demag chain

In addition to selecting the correct hoist unit for the given application, owners of chain hoists are obliged by rele‐ vant regulations – such as DIN 685 part 5 – to check the round-section steel chain continuously in operation to ensure optimum operating safety and, therefore, to avoid any accidents.

For single-shift operation, operation according to FEM classification and for chain hoist operating conditions ac‐ cording to  "Operating conditions", Page 27, the chain should be checked once a year (see inspection and maintenance schedule).

If routine maintenance reveals that the intervals are too long, they should be adapted to the specific operating conditions.

Visual inspection of the chain

Carry out a visual inspection of the chain before starting work. If the chain displays deformation, damage, cracks, pitting from corro‐ sion, reduction in the link thickness or increase in pitch dimension due to wear or elongation as a result of plastic deformation, the chain must be replaced immediately.

Fig. 43 Chain wear

214 802 44/291113

Measuring wear or deformation of the original Demag chain

Two methods can be used to measure wear or deformation of the original Demag chain:

● Measuring with a calliper gauge:

wear of a single chain link  Fig. 44, Page 75;

on 11 chain links  Fig. 45, Page 75.

● Measuring with a chain gauge:

on 11 chain links  Fig. 46, Page 76.

Measuring wear of a single chain link with a calliper gauge

Fig. 44

The chain link contact areas must be visually checked for traces of wear. If the chain hangs at angle when no load is attached to it, for example, this usually indicates wear of an individual chain link.

Measure the diameter of the chain link material in the chain link contact area using a calliper gauge, if required. For minimum link diameter values, see  "Tab. 53", Page 75.

Measuring with a calliper gauge on 11 chain links

A partial load must be suspended from the load hook when measuring the chain over 11 links. Measurements on 11 chain links may be taken in steps of 2 x 3 and 1 x 5 chain links. The sum total of the 3 readings taken, i.e. a

+ a2 + a3 must not exceed

the specified limit a. Otherwise the chain must be replaced. Demag is stamped on every 12th link of genuine Demag chains. Do you find that, on fitting a new chain, it does not run smoothly over the sprocket? Please contact our after-sales service centre. We strongly recommend that you use genuine Demag chains. This will ensure that the safety and service life of the chain hoist is guaranteed.

Fig. 45

Demag chain hoist DC 1 - 2 DC 5 DC 10

Chain designation d x t [mm] 4,2 x 12,2 5,3 x 15,2 7,4 x 21,2

Limit dimensions according to DIN 685 part 5

Measurement over the outside of 11 chain links, maximum dimension a = a

Overall length of 1 chain link inside, max. dimension t

Measurement of the chain link diameter, minimum dimension d

Tab. 53

+ a 2 + a

= 0,9 x d

[mm] 144,7 180,3 253

[mm] 12,8 15,9 22,4

[mm] 3,8 4,8 6,7

214 802 44/291113

The limit dimensions apply to all hoist chains listed in  "Available hoist chains", Page 77.

Measuring with a chain gauge on 11 chain links

Fig. 46

A DC / DK / PK new chain 2

B PK old chain 3 Measuring pin

1 Chain gauge, part no. 836 025 44 4 11. th chain link; the chain is ready to be discarded. The chain must be replaced.

Tab. 54

It does not yet need to be discarded. The chain does not yet need to be replaced. The chain needs to be replaced if the measuring pin can no longer be inserted into the 11th chain link.

A partial load must be suspended from the load hook when measuring the chain over 11 links.

8.5.5.5 Chain set scope of supply

The chain must be replaced when the permissible chain wear limit is reached (to determine the wear limit of the chain, see  "Checking the hoist chain", Page 74). A chain set is always supplied when a new standard RDC/TDK chain is ordered. The chain set includes the following parts:

● Chain,

● Sprocket,

● Chain guide with plate and cap,

● Chain guide plate,

● Buffers for upper and lower hook position,

● Tube of Demag chain grease,

● Retaining ring.

The chain guide is pre-assembled, the chain is already fitted in the chain guide.

214 802 44/291113

8.5.5.6 Available hoist chains

Genuine Demag chain is a round-section steel chain tested to EN 818-7 which is subject to the regulations for round-section steel chains used in hoist applications issued by the Main Association of Industrial Employers' Mu‐ tual Insurance Societies, Central Department for Accident Prevention and the test criteria for round-section steel chains used in hoist applications and the inspection regulations to DIN 685 part 5 of Nov. 1981 as well as BGV D8 and BGV D6.

CAUTION

Pay attention to reduced load capacities.

For non-standard operating conditions, the special chains listed below are available for special ambient condi‐ tions.

Chain hoist

Demag RDC/TDK standard chain

Properties

Material Ni-Mo special chain steel to EN 818-7, part 5.3.1

Lubrication GP00H-30REN.SO-GFB grease

Demag Corrud special chain

Application, e.g. galvanising, electro‐ plating facilities

Properties Ageing-resistant, corrosion-free, "Corrud DS" micro-layer corrosion protection, black-coated, colour: black, Stabylan 2001

Material Ni-Mo special chain steel to EN 818-7, part 5.3.1

Lubrication Acid-resistant chain grease, e.g. GLEITMO 582

Demag HS7 special chain

Application, e.g. foundry, dust, em‐ ery, blasting

Properties Ageing-resistant, blue-chromated, with deeper surface hardening

Material Ni-Mo special chain steel to EN 818-7, part 5.3.1

Lubrication Dry or with dry lubricant, e.g. Ceplatlyn 300

Demag RS6 special chain

Application, e.g. foodstuffs sector

Properties Non-rusting chain, not hardened, bright

Material Stainless steel AISI 316 (V4A) 1,4401

Lubrication Food-safe lubricant, e.g. Paraliq chain spray

Tab. 55

size

DC 1 - 2 250 - 4,2 x 12,2

DC 10 1250 2500 7,4 x 21,2 1,20 43 70

High-strength ageing-resistant material with a high degree of surface hardening, galvanised with additional surface treatment, blue-chro‐

DC 1 - 2 250 - 4,2 x 12,2

DC 10 1250 2500 7,4 x 21,2 1,20 43 70

DC 1 - 2 160 - 4,2 x 12,2

DC 10 800 1600 7,4 x 21,2 1,20 38,7 60

DC 1 - 2

DC 10

Max. load capacity for reeving Dimension Stamp,

1/1 2/1

[kg] [kg] [mm] [kg] [kN] [kN] [%]

mated, colour: silver

23)

125

200

400

23)

- 160

- 250

- 500

24)

- 4,2 x 12,2

- 5,3 x 15,2 0,62 16 25

800

25)

- 1000

26)

7,4 x 21,2 1,20 32 50

chain quality

DAT

RDC/TDK

DAT

RDC/TDK

RSX / DS

RSA / S

Weight per

metre

0,38 13,8 22

0,38 12,5 19,3

0,38 10 16

Production

test force

Minimum

breaking

force

Minimum

elongation

at rupture

10DC 5 500 - 5,3 x 15,2 0,62 22 35

5DC 5 400 - 5,3 x 15,2 0,62 19,8 30,8

15DC 5

214 802 44/291113

23)

For max. 25 - 50 cycles per day

24)

For max. 10 cycles per day

25)

For max. 12 - 25 cycles per day

26)

For max. 5 cycles per day

8.5.5.7 Replacing the chain set

Fig. 47

Before starting any maintenance work, switch the hoist off and secure it against reconnection to the power supply. To replace the chain set, proceed as follows:

1. Open and remove service cover (1).

2. Place bag (2) with the control cable on the chain hoist; pull out mains cable union (3) with fitted mains cable (4) and place to one side; if a travel drive is fitted, remove the connecting cable from the strain relief arrange‐ ment;

3. Loosen cap (5) with a screwdriver (lever off);

Remove chain collector box (6) and set it down ( "Removing the chain collector box", Page 71);

214 802 44/291113

Fig. 48

1. Remove guide plate (7);

2. Remove retaining ring (8) using ring pliers; either use straight or offset pliers (access through the opening in the gearbox housing on the side of the motor or from the service enclosure);

DC-Com 1 to 5: In the area power supply insert;

DC Com 10: Fold cover (9) of the opening in the gearbox housing to the side.

3. Remove chain guide (10) with the sprocket from the output shaft; to do this, slide the complete assembly in the direction of the motor until the sprocket is free; the worn chain can then be removed from the service enclosure.

Proceed in reverse order to install the new chain set.

Pay attention to the following points:

214 802 44/291113

Chain hoist with geared limit switch

Fig. 49

A) Chain guide for DC 10 without geared limit switch B) Chain guide for DC 10 with geared limit switch

Tab. 56

The chain guide has a larger opening on chain hoists that are equipped with a geared limit switch.

8.5.5.8 Lubricating the hoist chain

After fitting, before a test load is lifted and before the hoist is put into operation as well as during normal opera‐ tion when no load is attached, the chain link contact areas must be lubricated with gear grease, part no. 665 009 44.

The chain link contact areas must be relubricated appropriately – after being cleaned – at intervals depending on the service and load conditions. A dry film lubricant should be used in environments where abrasives occur (em‐ ery, sand, etc.). For non-standard lubrication, see  "Available hoist chains", Page 77.

CAUTION

Premature wear of the chain.

Danger of load being dropped due to broken chain.

The chain must be lubricated along its entire length.

Even chain links which are covered, e.g. in the chain anchorage, hook assembly, limit stop or crab frame, must be fully lubricated.

DC 1-10 chain hoist

Fig. 54

Cut off the tip of the grease tube and insert the grease tube at the lubri‐ cation point. Insert grease into the chain guide by pressing the tube while you run the chain to its end positions to ensure complete and even lubrication of the chain.

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8.5.6 Load hook

8.5.6.1 Checking the load hook

Fig. 55

8.5.6.2 Hook safety catch

If the hook safety catch has to be replaced, turn the nut on the bolt until at least two turns of the thread can be seen on the other side of the nut. The bolted connection must only be tightened enough to allow the hook safety catch to move freely.

Load capacity [kg] 125 250 500 1250 2000

Chain hoist DC-Com 1 2 5 10

Reeving 1/1 2/1

Load hook Type T010 T020 T04 V 5

a1 28 34 40 50

27)

nom

max

b1 16 21 27 29

Dimensions [mm]

Max. test force [kN] 6 13 25 50

Max. hook force [kN] 13 25 50 100

Tab. 59

h1 20 26,1 34 44

28)

nom

min

L2 20 24 28 45

L4 82 94 116 159

d1 15 17 20 41,8

22,8 25,4 33,7 43

25,08 27,94 37,07 47,3

16,9 21,8 27,7 36

16,055 20,71 26,315 34,2

8.5.6.3 Checking the return sprocket

The return sprocket must be checked every month to ensure that it turns easily. To do this, any load bars attach‐ ed to the bottom block have to be removed. Check to ensure the bottom blocks moves easily during lifting and lowering operations. Abrupt movements of the bottom block indicate wear. We recommend that the return sprocket should be replaced every second time the chain is replaced.

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27)

Permissible deviation +10%

28)

Permissible deviation -5%

8.5.6.4 Replacing the hook with fittings for 1/1 reeving

DANGER

Fig. 56

– Remove the existing hook.

Remove both bolts (4) from the new hook.

Remove the upper half of the hook assembly.

Load may be dropped

Incorrect assembly may cause loads to be dropped.

During assembly, ensure:

– that chain link sections (1) are positioned with their collar in bearing (2). Grease the bearing and bearing

seat.

– that retaining pin (3) is correctly fitted when the hook and fittings are assembled.

– Tighten housing bolts (4) according to the tightening torque table.

Tightening torques [Nm] DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10

Hook assembly 6,8 9,5 25,0

Tab. 60

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8.5.6.5 Replacing the bottom block (standard) with internal cut-off springs for 2/1 reeving

Fig. 57

1. Remove guide half sections (1) (four M 6 bolts);

2. Remove bottom block retaining bolts (2) and remove the bottom block.

3. Insert the new chain into the bottom block in the same position and orientation (chain must operate without any twist);

4. Re-assemble the bottom block and tighten bolts (2) to a torque of 52 Nm;

5. Check correct fit of the four cut-off springs (3) in new halves (4) of the bottom block;

6. Install new guide half sections (1) and tighten bolts (5) to a torque of 5,5 Nm;

7. Apply the load capacity plate;

8. Perform a function check (run against the operating limit switches and check against the 7-segment display).

Tightening torques [Nm] DC 10

Bottom block with internal cut-off springs

Tab. 61

Bottom block halves 52,0

Guide section halves 5,5

Bottom block as of approx. 09/2009

As of approx. 09/2009, the bottom block is provided with rubber lips (1) at the chain entry points. The rubber lips should be checked for wear and correct fit during the annual inspection.

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Fig. 58

8.5.6.6 Replacing the bottom block (option) with external cut-off springs for 2/1 reeving

Fig. 59

Tightening torques [Nm] DC 10

Bottom block with external cut-off springs 55,0

Tab. 62

8.5.7 Buffer (only with optional operating limit switches DC-Com 1-10 with 1/1 reeving)

8.5.7.1 Checking the cut-off buffers/cut-off springs

Fig. 60

1. Buffer wear:

Visually check the buffers in the course of the annual inspection. Check for damage, cracks and tears.

2. Missing buffer plate:

Ensure that the component parts are installed in the right order when new buffers are installed (see also  "Buffer arrangement", Page 87). A missing buffer plate, for example, will result in premature wear of the buffer.

3. Wear of external cut-off springs:

Visually check the external cut-off springs in the course of the annual inspection. Check the sleeves of the springs for cracks and damage. The individual windings of the springs must not cross over each other.

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8.5.7.2 Buffer arrangement

Buffer variants

Fig. 61

1 Buffer 2 Buffer plate

3 Cut-off spring

Chain hoist range Load hook side Chain collector box side

DC-Pro 1 - 10

DC-Com 1 - 10 with operating limit switch

DC-Pro 1 - 10 CD

DC-Com 1 - 10 without operating limit switch E F

DC-Pro 1 - 10 GH

DC-Pro 15 JK

Tab. 63

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8.5.8 Brake

8.5.8.1 Brake assignment

Load capacity Chain hoist Reeving Motor size Brake Max. brake displacement

[kg] DC-Com [mm]

80 - 125 1

160 - 250 2

315 - 500 5 ZNK 80 A 8/2

630 - 1000

1250 - 2000 2/1 ZNK 100 B 8/2

Tab. 64

8.5.8.2 Check brake wear

Check brake wear depending on the year of manufacture of your chain hoist:

●

When the max. brake displacement is reached (see  Tab. 64, Page 88), the brake must be replaced immedi‐ ately.

● For brake displacement up to 0,5 mm, the brake can still be used until the next maintenance is due.

As of year of manufacture 04/2009

ZNK 71 B 8/2

1/1

ZNK 100 A 8/2

BK03

0,6

BK07

Fig. 62

Since 04/2009 – depending on the size of model – brakes have been gradually equipped with a plug inside the brake housing to enable brake wear to be measured without the need to remove the brake. Brake wear is meas‐ ured by the air gap.

Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on again.

● Open the electric equipment cover.

● Unscrew brake plug screw (1) from the brake.

●

Check brake wear with feeler gauge (2) (see  Tab. 64, Page 88).

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Until year of manufacture 03/2009

Fig. 63

Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on again.

● Open the electric equipment cover.

● Disconnect brake connector.

● Dismantle brake.

Measure brake wear with calliper gauge as follows:

● Measure the distance from the back of the brake to the brake disc with a depth gauge or calliper gauge when

the brake is not actuated.

● Measure the distance from the back of the brake to the brake disc with a depth gauge or calliper gauge when

the brake is actuated; to do this, press the brake disc against the springs until it stops.

● Use both measured values to calculate the difference; this difference is the brake displacement.

Assembly and maintenance

Fig. 64

When the brake is installed, make sure that the area of the V sealing ring (1) on the brake base is lightly greased. Ensure that no grease penetrates inside the brake. The continuous sealing lip must be in full contact with the back of the brake.

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In the course of the annual inspection, V sealing ring (1) of the brake must be re-greased with anti-friction bearing grease without any solid lubricant.

Tightening torques [Nm] DC 1 / 2 / 5 / 10

Brake 5,5

Electric equipment cover 9,5

Tab. 65

8.5.9 Slipping clutch

8.5.9.1 Checking the slipping clutch

Fig. 65

The slipping clutch provides the function of an emergency limit stop de‐ vice and overload protection for the chain hoist. The slipping clutch is initially adjusted in the factory. Under normal op‐ erating conditions, the slipping clutch does not need to be re-adjusted. The slipping clutch must be checked as part of the annual inspection. The slipping clutch may only be adjusted by authorised specialists. An increase of the tripping torque which exceeds the factory setting is not permitted.

Check operation of the slipping clutch as follows:

● The chain collector must be disconnected in order to remove the limit stop,  "Removing the chain collector box", Page 71. Remove the limit stop  Fig. 53, Page 81 from the section of chain which is not under load and fit it above the hook assembly. Run the limit stop against the guide plate at creep speed. The operating limit switches – if fitted – must not be actuated while this is being done.

If the slipping clutch is working correctly, the following will be observed:

● the hoist motor fan is still turning while there is no lifting motion;

●

The 7-segment display shows the SLIP LIFTING V1 warning,  "Warning messages", Page 98.

When the slipping clutch function has been checked, the limit stop must be fitted again to the section of chain which is not under load.

8.5.9.2 Adjusting the slipping clutch

Fig. 66

The slipping clutch is protected against overload by slip monitoring, which means that it does not have to re-ad‐ justed until a general overhaul is carried out. If, owing to the operating conditions or due to malfunctions, the ad‐ justment needs to be checked, a friction force checking device,  part no. 836 708 44, must be used. Inspection and adjustment may only be carried out by an experienced technician in compliance with the "Friction force checking device" document  Tab. 3, Page 7.

The slipping clutch is adjusted to the load capacity of the chain hoist during the final inspection in the factory. An increase of the tripping tor‐ que which exceeds the factory setting is not permitted, see also  "Suspending the chain hoist", Page 40.

For DC-Com chain hoists that have a load capacity ≥ 1000 kg, the set‐ ting meets the requirements of EN 14492 2 for slipping clutches used as overload protection. Overload protection must be provided for load capacities ≥ 1000 kg. If an acceptance check of the hoist or crane installation is carried out, a load of 110% of the rated load capacity must be lifted (without adjust‐ ment of the slipping clutch) as part of the dynamic overload test. A load > 160% must not be lifted, (EN 14492-2 "Direct acting rated capacity limiters").

214 802 44/291113

8.5.10 Gearbox/oil change

Fig. 67

Chain hoist size DC 1 - 2 DC 5 DC 10

Oil quantities [l] 0,35 0,50 0,90

Tightening torques

Tab. 66

Gearbox cover [Nm] 5,5

Service cover [Nm] 5,5 7,5

CAUTION

Dispose of waste oil in accordance with environmental protection requirements.

Oil lubrication Under normal operating conditions, the lubricant must be changed at least every 10 years. Under exceptional conditions, e.g. increased ambient temperatures, we recommend that oil changes be adapted to suit these condi‐ tions.

Oil grades Demag special oil with wear-minimising additives, range of viscosity 10W-30 (part no. 664 020 44) for slipping clutch without speed monitoring. Malfunctions of the slipping clutch may occur if oils are used that are not ap‐ proved. Contact the manufacturer for ambient temperatures lower than -20 °C or higher than +45 °C.

Safe operation cannot be ensured

Malfunctions of the slipping clutch may occur if oils are used that are not approved and safe operation can then no longer be ensured.

General remarks on oil changes Drain the old oil at operating temperature. Turn the gearbox in such a way that the oil is drained. The flushing oil should have a viscosity of 46-68 mm

/s at rated temperature. The quantity of flushing oil used should be approxi‐ mately twice that specified for lubrication. Then flush the gears by switching the hoist on and allowing the hook to run several times over the entire length of its lifting path. Then drain the flushing oil and refill the gearbox with new oil. Please refer to the table above for the required oil quantities. See spare parts for the order no.

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DC 1 - 10: Remove control unit with plug-and-socket connections (2) under electric equipment cover (3). Now re‐ move the screws of gearbox cover (1).

8.5.11 Replacing the contactor on the control board

Fig. 68

1. Unclip the contactor retaining mechanism by pressing locking tab (A) with your thumb. This carefully bends locking tab (A) away from the contactor.

2. Then turn contactor (B) using your other hand until the mechanism no longer holds it.

3. Then unclip second locking tab (A) on the opposite side (as described in step 1 above).

4. Using your other hand, remove contactor (B) by pulling it away from the board.

The replacement contactor can only be inserted into the socket in one position. Push the contactor into contactor socket (C) until both locking tabs (A) click into position.

214 802 44/291113

The contactors are also socket-mounted for sizes DC 1 to 5 manufactured as of 02/2011 and can be individually replaced.

214 802 44/291113

8.5.12 Replacing the control cable

Fig. 69

DANGER

Live components

Danger to life and limb.

Work on the electric equipment may only be carried out by a qualified electrician or by trained personnel.

214 802 44/291113

1. Disconnect the chain hoist from the power supply (mains connection switch) and secure it against switching on again.

Open and disconnect the service cover.

2. Remove and open bag (1) with the control cable.

3. Take the control cable out of the bag.

4. Turn and disconnect bayonet lock (2) and remove the control cable plug connector.

5. Unscrew electric equipment cover.

6. Loosen screw (3) on the control cable locking mechanism and remove the locking mechanism. Remove the control cable.

Install the new control cable in reverse order.

It must be ensured that

● the groove on the connector holder lines up with the swivel lock in the electric enclosure and

● that the two pins on the enclosure line up with the bayonet lock.

Assemble the control pendant  "Connecting the control pendant", Page 35.

Adjust the height of the control pendant  "Control pendant height adjustment", Page 37.

Tightening torques [Nm] DC-Com 1 DC-Com 2 DC-Com 5 DC-Com 10

Electric equipment cover 9,5

Service cover 5,5 7,5

Control cable locking mechanism 11,0

Tab. 67

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9 Malfunctions/warnings

9.1 Safety instructions for malfunctions/warnings

WARNING

Inappropriate fault elimination

Danger to life and limb. Risk of damage to the machine.

Faults may only be eliminated by qualified instructed personnel ( "Definition of personnel", Page 10) in compli‐ ance with the safety regulations.

DANGER

Live components

Danger to life and limb.

Work on electric equipment may only be carried out by qualified specialist personnel ( "Definition of person‐ nel", Page 10) in compliance with the safety regulations.

WARNING

Risk of burns

Risk of burns from contact after the chain hoist has been in operation.

Do not touch hot motor housings. Allow the motor to cool down before elmininating the fault.

Conduct when malfunctions occur

1. Bring the machine to an immediate standstill by actuating the emergency stop without delay if malfunctions occur that result in an immediate danger of personal injury, damage and/or an operating hazard.

2. Switch the chain hoist off at the mains connection switch or isolating switch and secure it against switching on again.

3. Inform the person responsible at the location about the malfunction.

4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐ sonnel.

Conduct after a malfunction is eliminated

Check for correct assembly

Before reconnecting the power supply, ensure that

– Malfunction and cause of malfunction have been eliminated.

– All safety devices have been fitted properly and are in perfect condition and working order.

– Nobody is present in the danger zone of the equipment.

9.2 7-segment display

The 7-segment display is located on the underside of the chain hoist behind a window.

Fig. 70

Warning messages start with a lightning symbol. Movement in the opposite direction is possible, the warning message does not need to be acknowledged using the emergency stop.

214 802 44/291113

Error messages start with an "E" for error. Before any further movement is possible, the error message must be acknowledged using the emergency stop.

Fig. 71

Safety function failure If a safety function fails, the equipment must not be operated until it is repaired.

Malfunctions The chain hoist can only function when it is correctly connected to the power supply. In the event of a failure, therefore, first check cables, strain relief and power supply connections. Malfunctions may also be caused by in‐ correct transmission of commands from the control pendant. Therefore, check the control pendant and the control cable for damage and the plug-in connector on the pendant and in the service enclosure for correct fit.

The symbols are shown one after the other.

● Please contact our after-sales service if the cause of the fault cannot be eliminated with the given measures.

9.3 Operating statuses/general messages

Fig. 72

Item Display Malfunction/event Possible cause Remark

Tab. 68

No lifting, no lowering. No power supply (display is dark) Check mains connection and fuse link; check connection

No lifting, no lowering. Emergency stop actuated. Unlock emergency stop by turning it.

Cables not connected or defective. Check and replace connections, as required.

Plug connections not connected or defective. Check and replace plug connections, as required.

- - Flashing: READY

No lifting, no lowering.

- - Operating mode: Lifting V1

- - Operating mode: Lowering V1

- - Operating mode: Lifting V2

- - Operating mode: Lowering V2

- - Operating mode: Lifting start-up

- - Operating mode: Lowering start-up

Incorrect motor direction of rotation.

Thermal contact open.

Upper or lower limit position has been reached. Actuate opposite direction.

When the voltage is switched on or the emergencystop is unlocked, a button is already actuated.

Control cable interrupted.

cable for interruption; check mains connector in the service enclosure. Check PE phase for correct connection.

Two phases of the mains connection cable must be changed. First disconnect unit from the power supply.

Check motor plug connector X8 for continuity between ter‐ minals 4 and 8.

Release button and actuate it again.

Check connections of the control cable on the pendant and in the service enclosure. Check control cable for continuity.

214 802 44/291113

9.4 Warning messages

In general, all warning messages are generated by comparison of the actual and theoretical speed. There may be various causes for a difference in speed:

● incorrectly adjusted slipping clutch;

● a binding brake or

● a dirty or defective speed sensor.

These causes may result in frequent warning messages. Various measures must be taken to eliminate the warning messages:

- clean the speed sensor with compressed air (e.g. dirt accumulation on the photo cell);

- check and, if necessary, adjust the slipping clutch;

- check and, if necessary, adjust the brake air gap.

Fig. 73 Display examples

Item Display Malfunction/event Possible cause Remark

Tab. 69

.1. SLIP LIFTING start-up: No

lifting. No lifting with load.

.2. SLIP LIFTING V1: Cut-out

in the upper limit position.

.3. SLIP LIFTING V2: Cut-out

in the upper limit position. Fast lifting with load is switched off.

.4. Defective internal data

memory.

.6. No speed information. Hardware monitoring malfunction. Repeat lifting process; if the load does not move, have the

.7. SLIP LOWERING start-up:

No lowering.

.8. SLIP LOWERING V1: Low‐

ering is switched off, lower limit position is not reached. Cut-out in the lower limit position

.9. SLIP LOWERING V2: Low‐

ering is switched off, lower limit position is not reached. Cut-out in the lower limit position

A mains phase is missing or the motor is blocked. Check mains connection and fuse link; check connection

cable for interruption; check mains connector in the service enclosure.

Chain hoist overloaded or undervoltage. Reduce load to the permissible load capacity. Ensure ap‐

propriate mains voltage.

Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.

The slipping clutch acts as an emergency-stop device if there is a malfunction. Limit switch contact connection and operation must be in‐ spected by an experienced technician.

Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.

The slipping clutch acts as an emergency-stop device if there is a malfunction. Limit switch contact connection and operation must be in‐ spected by an experienced technician.

Chain hoist overloaded. Reduce load to the permissible load capacity.

Defective control system. Replace control system.

brake and control system checked by an experienced tech‐ nician.

A mains phase is missing or the motor is blocked. Check mains connection and fuse link; check connection

cable for interruption; check mains connector in the service enclosure.

Chain blocked. Check chain entry point, replace chain, if required.

Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.

The slipping clutch acts as an emergency-stop device if there is a malfunction. Limit switch contact connection and operation must be in‐ spected by an experienced technician.

Chain blocked. Check chain entry point, replace chain, if required.

Limit switch contact is no longer actuated. (-.) is displayed when the limit switches function correctly.

The slipping clutch acts as an emergency-stop device if there is a malfunction. Limit switch contact connection and operation must be in‐ spected by an experienced technician.

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9.5 Error messages

Fig. 74 Display examples

Item Display Malfunction/event Possible cause Remark

1 E.1. Chain hoist is blocked. Hardware error of control system. Check error message by actuating and unlocking the emer‐

Defective electronic monitoring. Replace hoist control system.

Defective "On/off" contactor

Contact wear

2 E.2. Chain hoist is blocked. Drive blocked. Check error message by actuating and unlocking the emer‐

Speed measurement failure. Replace hoist control system.

3 E.3. Hoist unit: overspeed or

load cannot be held. Low‐ ering with load is switched off.

5 E.5. Chain hoist is blocked. Hardware error of control system. Check error message by actuating and unlocking the emer‐

6 E.6. Chain hoist is blocked. Hardware error of control system. Check error message by actuating and unlocking the emer‐

7 E.7. Hoist unit: Motor runs in

wrong direction. Chain hoist is blocked.

8 E.8. Lifting is switched off. Brake defective or slipping clutch incorrectly adjus‐

9 E.9.9. Chain hoist is blocked. Emergency-stop circuit of control system defective. Check error message by actuating and unlocking the emer‐

Tab. 70

Lowering speed too high. Reduce load to the permissible load capacity. Check mains

Defective electronic monitoring. Replace hoist control system.

Direction of hoist unit cannot be switched. Check error message by actuating and unlocking the emer‐

ted.

gency stop. Then actuate Lowering. If necessary, remove suspended load.

Replace contactor,  "Replacing the contactor on the con‐ trol board", Page 92

gency stop. Then actuate Lowering. If necessary, remove suspended load.

connection and fuse link; check connection cable for inter‐ ruption; check mains connector in the service enclosure.

gency stop. Then actuate Lowering. If necessary, remove suspended load.

Replace hoist control system.

Check brake and slipping clutch.

If there is no fault, replace electronics.

gency stop. Then actuate Lowering. If necessary, remove suspended load.

Replace hoist control system.

214 802 44/291113

Hardware faults are displayed with two characters by software version 1.60 and higher.

10 Disassembly/disposal

10.1 General

WARNING

Before disassembly, follow the safety instructions in  "Maintenance/repair", Page 62 of these operating in‐ structions.

Refer to  "Assembly", Page 32 of these operating instructions for information on removing track sections, trol‐ leys and current collector trolleys. Other parts are removed in reverse order to assembly.

Unless a return or disposal agreement has been concluded, separated components must be recycled after proper removal:

● Scrap any remaining metallic material,

● Dispose of plastic elements for recycling,

● Separate and dispose of any other components by material type.

Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special disposal regulations and may only be disposed of by certified companies.

National disposal regulations must be considered regarding environmentally friendly disposal. Further information can be obtained from corresponding local authorities.

100

214 802 44/291113

DEMAG DC-Com 1, DC-Com 10, DC-Com 2, DC-Com 5 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Operating instructions/accessories/component parts

Table of contents

1 General

1.1 DC-Com chain hoist

1.2 DC-Com documents

1.3 Symbols/signal words

1.4 Information on the operating instructions

1.5 Liability and warranty

1.6 Copyright

1.7 Use of spare parts

1.8 Definition of personnel

1.9 Test and inspection booklet

1.10 After-sales service

2Safety

2.1 General information on safety

2.2 Safety signs on the equipment

2.3 Intended use

2.4 Hazards that can be caused by the machine

2.5 Responsibility of the owner

2.6 Operating personnel requirements

2.7 Personal protection equipment

2.8 Emergency-stop device

2.9 Regular inspections

3 Technical data

3.1 Design overview

3.2 Model code

3.3 Selection table

3.4 Electric key data

3.4.1 Hoist motor data

3.4.2 Mains connection delay fuse links

3.4.3 Supply cables

3.5 Hook dimension C

3.6 Noise emission/sound pressure level

3.7 Transport, packing and storage

3.7.1 Safety instructions

3.7.2 Scope of delivery

3.7.3 Transport inspection

3.7.4 Packing

3.7.5 Storage

3.8 Materials

3.8.1 Linings

3.8.2 Housing

3.8.3 Surface protection and paint finish

3.9 Operating conditions

4 Technical description

4.1 Drive and brake

4.2 Gearbox and slipping clutch

4.3 Chain drive

4.4 Electric equipment

4.4.1 Control system

4.4.2 7-segment display for operating status and fault display

4.4.3 Display of software version, operating hours, number of cycles

4.5 Central service enclosure

4.6 Control pendant/control cable height adjustment

4.7 Control pendant

5 Assembly

5.1 General

5.2 Safety instructions for assembly

5.3 DC-Com chain hoist tightening torques

5.4 Installation procedure

5.5 Connecting the control pendant

5.6 Control cable

5.6.1 Control cable technical data

5.6.2 Handling the control cable

5.6.3 Control pendant height adjustment

5.6.4 Mobile control system

5.7 Suspending the chain hoist

5.7.1 Supporting structure

5.7.2 Suspension bracket

5.8 Mains connection

5.9 Circuit diagrams and control boards

5.9.1 DC-Com 1 - 10 solo hoist circuit diagram

5.9.2 Circuit diagram with E11 - E34 DC travel drive

5.9.3 Control board

5.10 Programming parameters with the control pendant

5.10.1 General